6.4c engine control system - new 1.2l b12-mce

Engine Control System （1.2L）

6.4C Engine Control System - New 1.2L（B12-MCE）

Chapter 6

Engine

6.4C Engine Control System - New 1.2L（B12-MCE） 1 6.4C.1 Specifications(N300/N310) ................................ 4 6.4C.1.1 Fastener Tightening Specifications ................. 4 6.4C.2A Circuit Diagram (N300) .................................... 5 6.4C.2.1 Routing diagrams ............................................ 5 6.4C.2.2 View of engine control module (ECM) end ..... 7 6.4C.2.2 View of engine control module (ECM) end . 11 6.4C.3A Description of engine control system connector (N300) .......................................................................... 13 6.4C.3.1 Electronic throttle........................................... 13 6.4C.3.2 Water temperature sensor............................. 13 6.4C.3.3 Intake pressure sensor .................................. 13 6.4C.3.4 Canister solenoid valve ................................. 13 6.4C.3.5 Back oxygen sensor ...................................... 14 6.4C.3.6 Front oxygen sensor ..................................... 14 6.4C.3.7 Crankshaft position sensor ............................ 14 6.4C.3.8 Intake side camshaft position sensor ............ 14 6.4C.3.9 EGR valve ..................................................... 15 6.4C.3.10 Intake air temperature sensor ..................... 15 6.4C.3.11 Vehicle speed sensor .................................. 15 6.4C.3.12 Knock sensor ............................................... 15 6.4C.3.13 Intake side VVT control ............................... 16 6.4C.3.14 Air conditioning evaporator temperature sensor .......................................................................... 16 6.4C.3.15 Ignition coil 1 ............................................... 16 6.4C.3.16 Ignition coil 2 ............................................... 16 6.4C.3.17 Ignition coil 3 ............................................... 17 6.4C.3.18 Ignition coil 4 ............................................... 17 6.4C.3.19 Fuel injector 1 .............................................. 17 6.4C.3.20 Fuel injector 2 .............................................. 17 6.4C.3.21 Fuel injector 3 .............................................. 18 6.4C.3.22 Fuel injector 4 .............................................. 18 6.4C.3.23 Fuel pump ................................................... 18 6.4C.3.24 Electronic accelerator pedal ........................ 18 6.4C.3.25 Electronic clutch switch ............................... 19 6.4C.3.27 Service brake switch ................................... 19 6.4C.3.1 Electronic throttle valve .............................. 20 6.4C.3.2 Water temperature sensor .......................... 20 6.4C.3.3 Intake air pressure sensor .......................... 20 6.4C.3.4 Canister solenoid valve .............................. 20 6.4C.3.5 Back oxygen sensor ................................... 21 6.4C.3.6 Front oxygen sensor ................................... 21 6.4C.3.7 Crankshaft position sensor ......................... 21 6.4C.3.8 Air inlet side camshaft position sensor ....... 21 6.4C.3.9 EGR valve ................................................... 22 6.4C.3.10 Intake air temperature sensor ................... 22 6.4C.3.11 Vehicle speed sensor ................................ 22 6.4C.3.12 Knock sensor .......................................... 22 6.4C.3.13 Air inlet side VVT control ............................. 23 6.4C.3.14 Air conditioning evaporator temperature sensor .......................................................................... 23 6.4C.3.15 Ignition coil1 1 ........................................... 23 6.4C.3.16 Ignition coil 2 ............................................. 23 6.4C.3.17 Ignition coil 3 ............................................. 24 6.4C.3.18 Ignition coil 4 ............................................. 24

6.4C.3.19 Fuel injector 1 ........................................... 24 6.4C.3.20 Fuel injector 2 ........................................... 24 6.4C.3.21 Fuel injector 3 ........................................... 25 6.4C.3.22 Fuel injector 4 ........................................... 25 6.4C. 3.23 Fuel pump ................................................ 25 6.4C. 3.24 Electronic accelerator pedal .................... 25 6.4C. 3.26 Wheel speed sensor ................................ 26 6.4C. 3.27 Service brake switch ................................ 26 6.4C.4 Diagnostic information and procedures............ 27 6.4C.4.1 Diagnostic starting point ................................ 27 6.4C.4.2 Check of powertrain on-board diagnostic (OBD) system .......................................................................... 27 6.4C.4.3 Type definitions of diagnostic trouble code (DTC) ........................................................................... 30 6.4C.4.4 Inoperative Malfunction indicating lamp (MIL) ..................................................................................... 34 6.4C.4.5 Diagnosis of data link connector ................... 36 6.4C.4.6 DTC P0130 Upstream oxygen sensor circuit open ............................................................................. 38 6.4C.4.7 DTC P0136 Downstream oxygen sensor circuit open ............................................................................. 40 6.4C.4.8 DTC P0131 Upstream oxygen sensor circuit short to earth ................................................................ 42 6.4C.4.9 DTC P0137 Downstream oxygen sensor circuit short to earth ................................................................ 44 6.4C.4.10 DTC P0132 Upstream oxygen sensor circuit short to power .............................................................. 46 6.4C.4.11 DTC P0138 Downstream oxygen sensor circuit short to power .................................................... 48 6.4C.4.12 DTC P0031 Upstream oxygen sensor heater control circuit open or short to earth ............................ 50 6.4C.4.13 DTC P0037 Downstream oxygen sensor heater control circuit open or short to earth ................. 51 6.4C.4.14 DTC P0032 Upstream oxygen sensor heater control circuit short to power ........................................ 52 6.4C.4.15 DTC P0038 Downstream oxygen sensor heater control circuit short to power ............................. 53 6.4C.4.16 DTC P0106 Improper intake manifold pressure sensor signal ................................................. 54 6.4C.4.17 DTC P0107 Intake manifold pressure sensor circuit short to earth ..................................................... 56 6.4C.4.18 DTC P0108 Intake manifold pressure sensor circuit short to power .................................................... 58 6.4C.4.19 DTC P0112 Intake temperature sensor circuit short to earth ................................................................ 60 6.4C.4.20 DTC P0113 Intake temperature sensor circuit short to power .............................................................. 62 6.4C.4.21 DTC P0117 Engine coolant temperature sensor circuit short to earth .......................................... 64 6.4C.4.22 DTC P0118 Engine coolant temperature sensor circuit short to power or open ........................... 66 6.4C.4.23 DTC P0119 Engine coolant temperature sensor signal gradient failure ....................................... 68 6.4C.4.24 DTC P0123 Overtension of throttle position sensor 1 ....................................................................... 71


6.4C.4.25 DTC P0122 Low voltage of throttle position sensor 1 ....................................................................... 74 6.4C.4.26 DTC P0223 Overtension of throttle position sensor 2 ....................................................................... 77 6.4C.4.27 DTC P0222 Low voltage of throttle position sensor 2 ....................................................................... 80 6.4C.4.28 DTC P2135 Inappropriate voltage relativity of throttle position sensor 1/2 ........................................... 83 6.4C.4.29 DTC P2123 Overtension of accelerator position sensor 1 .......................................................... 84 6.4C.4.30 DTC P2122 Low voltage of accelerator position sensor 1 .......................................................... 85 6.4C.4.31 DTC P2128 Overtension of accelerator position sensor 2 .......................................................... 86 6.4C.4.32 DTC P2127 Low voltage of accelerator position sensor 2 .......................................................... 87 6.4C.4.33 DTC P2138 Inappropriate voltage relativity of accelerator position sensor 1/2 .................................... 88 6.4C.4.34 DTC P0627 Fuel pump relay circuit open ... 89 6.4C.4.35 DTC P0628 Fuel pump relay circuit short to earth ............................................................................. 91 6.4C.4.36 DTC P0629 Fuel pump relay circuit short to power ........................................................................... 93 6.4C.4.37 DTC P0201 1st cylinder fuel injector circuit open ............................................................................. 95 6.4C.4.38 DTC P0202 2nd cylinder fuel injector circuit open ............................................................................. 97 6.4C.4.39 DTC P0203 3rd cylinder fuel injector circuit open ............................................................................. 99 6.4C.4.40 DTC P0204 4th cylinder fuel injector circuit open ........................................................................... 101 6.4C.4.41 DTC P0261, P0264, P0267 and P0270 Cylinder 1/2/3/4 fuel injector circuit short to earth ..... 103 Circuit description ...................................................... 103 6.4C.4.42 DTC P0262, P0265, P0268 and P0271 Cylinder 1/2/3/4 fuel injector circuit short to power .... 105 6.4C.4.43 DTC P0300 Repeated misfire, P0301 Misfire 0 (cylinder 1), P0302 Misfire 3 (cylinder 2), P0303 Misfire 1 (cylinder 3), and P0304 Misfire 2 (cylinder 4) ................................................................................... 107 6.4C.4.44 DTC P0325 Knock sensor failure (signal pickup fault) ................................................................ 109 6.4C. 4.45 DTC P0325 knock sensor fault (signal value fault) ........................................................................... 111 6.4C.4.46 DTC P0336 Inappropriate/No/Losing synchronization of crankshaft sensor signal .............. 113 6.4C.4.47 DTC P0315 Flywheel self-adaption cycle time at limit state ................................................................ 115 6.4C.4.48 DTC P0373 Incorrect signal/signal cycle of crankshaft teeth ......................................................... 117 6.4C.4.49 DTC P0341 Inappropriate intake camshaft position sensor signal / intake camshaft position sensor signal cycle out-of-limit / intake camshaft position sensor with problematic sysnchronization ............................. 119 6.4C.4.50 DTC P0351, P0352, P0353, P0354 ignition coil 1 open circuit/ignition coil 2 open circuit/ignition coil 3 open circuit/ignition coil 4 open circuit .................... 121 6.4C.4.51 DTC P2300, P02303, P02306, P2309 1 cylinder/2 cylinder /3 cylinder/4 cylinder ignition coil short to earth .............................................................. 123 6.4C.4.52 DTC P2301, P02304, P02307, P2310 1 cylinder/2 cylinder /3 cylinder/4 cylinder ignition coil short to power ............................................................ 125 6.4C.4.53 DTC P0420 Low catalyst conversion

efficiency .................................................................... 127 6.4C.4.54 DTC P0444 Canister control valve circuit open ........................................................................... 129 6.4C.4.55 DTC P0458 Canister control valve circuit short to earth .............................................................. 131 6.4C.4.56 DTC P0459 Canister control valve circuit short to power ............................................................ 133 6.4C.4.57 DTC P0691 Cooling fan relay 1 circuit open or short to earth .............................................................. 135 6.4C.4.58 DTC P0692 Cooling fan relay 1 circuit short to power ......................................................................... 137 6.4C.4.59 DTC P0693 Cooling fan relay 2 circuit open or short to earth .............................................................. 139 6.4C.4.60 DTC P0694 Cooling fan relay 2 circuit short to power ......................................................................... 141 6.4C.4.61 DTC P0500 Inappropriate vehicle speed sensor signal .............................................................. 143 6.4C.4.62 DTC P0537 Air conditioning evaporator temperature sensor short to earth.............................. 145 6.4C.4.63 DTC P0538 Air conditioning evaporator temperature sensor circuit short to power or open .... 147 6.4C.4.64 DTC P0645 A/C compressor relay circuit open ........................................................................... 149 6.4C.4.65 DTC P0646 A/C compressor relay circuit short to earth .............................................................. 151 6.4C.4.66 DTC P0647 A/C compressor relay circuit short to power ............................................................ 153 6.4C.4.67 DTC P0685 Main relay circuit break to earth ................................................................................... 155 6.4C.4.68 DTC P0686 Main relay circuit short to earth ................................................................................... 157 6.4C.4.69 DTC P0687 Main relay circuit short to power ................................................................................... 159 6.4 C. 4.70 DTC P2413 EGR valve position self-learning error ............................................................................ 161 6.4 C. 4.71 DTC P0488 EGR valve position control error ................................................................................... 162 6.4 C. 4.72 DTC P0488 ETC electrical failure open circuit .......................................................................... 163 6.4 C. 4.73 DTC P0638 ETC_1 unreasonable output signal of position controller ........................................ 164 6.4C.4.74 DTC P0638 Unreasonable output signal of ETC_2 position controller ........................................... 165 6.4C.4.75 P060A Monitoring fault ........................... 166 6.4C.4.76 DTC P0016 Intake Camshaft Position Offset ................................................................................... 167 6.4C.4.77 DTC P2176 TPS cannot reach cutoff point/ TPS position self-leaning fault ................................... 168 6.4C.4.78 DTC P0121 Unreasonable throttle position sensor 1 signal and DTC P0221 unreasonable throttle position sensor 2 signal ............................................. 169 6.4C.4.79 DTC P0650 Malfunction indicating lamp circuit open, short to earth or short to power ............. 170 6.4C.4.80 DTC P0562 Low power supply voltage ..... 172 6.4C.4.81 DTC P0563 High power supply voltage .... 174 6.4C.4.82 DTC P0171 Fuel system diagnosis - too lean ................................................................................... 176 6.4C.4.83 DTC P0172 Fuel system diagnosis - too rich ................................................................................... 178 6.4C.4.84 DTC P0133 Slow conversion time response of upstream oxygen sensor ........................................ 180 6.4C.4.85 DTC P0643 High voltage of sensor supply voltage 1 circuit, P0642 Low voltage of sensor supply voltage 1 circuit, P0653 High voltage of sensor supply


voltage 2 circuit, and P0652 Low voltage of sensor supply voltage 2 circuit ............................................... 183 6.4C.4.86 DTC P0075 Intake VVT solenoid circuit open ................................................................................... 185 6.4C.4.87 DTC P0076 Intake VVT solenoid short to earth ........................................................................... 187 6.4C.4.88 DTC P0077 Intake VVT solenoid short to power ......................................................................... 189 6.4C.4.89 DTC P0487 EGR Valve Driver Open-circuit ................................................................................... 191 6.4 C.4.90 DTC P0489 EGR Driver short to earth ..... 193 6.4C.4.91 DTC P0490 EGR Driver short to power . 195 6.4C.4.92 DTC P0506 Too low speed by idle speed control and DTC P0507 Too high speed by idle speed control ........................................................................ 197 6.4C.4.93 DTC P0504 Inappropriate brake light and brake signals relativity ................................................ 198 6.4C.4.94 DTC P2299 Contradictory positions of the break and the accelerator pedal ................................ 200 6.4C.4.95 DCT P0406 EGR valve position signal high, DTC P0405 EGR valve position signal low ................ 201 6.4C.4.96 DTC P0135 unreasonable heating circuit of upstream oxygen sensor............................................ 202 6.4C.4.97 DTC P0134 preparation of upstream oxygen sensor uncompleted ................................................... 203 6.4C.4.98 DTC P2158 unreasonable wheel speed sensor signal .............................................................. 204 6.4C.4.99 DTC P0011 Camshaft position sensor offset in steady working condition ........................................ 205 6.4C.4.100 DTC P2118 throttle position signal deviation too large ..................................................................... 206 6.4C.4.101 DTC P2096 fuel correction too dilut/ P2097 fuel correction too dense............................................ 207 6.4C.4.103 DTC P2120 accelerator pedal disconnection diagnosis .................................................................... 209 6.4C.4.104 DTC P0141 unreasonabl heating circuite of downstream oxygen sensor ....................................... 210 6.4C.4.105 DTC P060C main controller monitoring fault ................................................................................... 211 6.4C.4.106 DTC P061A reasonability monitoring fault of required torque and actual torque P061B actual or required torque exceeding the allowable value. ........ 212 6.4C.4.107 Symptom ................................................. 213 6.4C.4.108 Intermittent conditions ............................. 214 6.4C.4.92 Starting difficulty ........................................ 215 6.4C.4.110 Surges/chugging ...................................... 216 6.4C.4.111 Lack of power, sluggishness or sponginess ................................................................................... 217 6.4C.4.112 Knock/spark knock .................................. 218 6.4C.4.113 Hesitation, sag and stumble .................... 219 6.4C.4.114 Power failure or insufficiency ................... 220 6.4C.4.115 Poor fuel economy................................... 222 6.4C.4.116 Rough, unstable or incorrect idle and stalling ................................................................................... 223 6.4C.4.117 Dieseling and run-on ............................... 224 6.4C.4.101 Backfiring ................................................. 225 6.4C.4.119 Diagnosis of engine control module ........ 226 6.4C.4.120 The air-conditioning circuit controlled by engine control module ................................................ 230 6.4C.4.121 Diagnosis of electric cooling fan.............. 233 6.4C.4.122 Check of fuel tank leak ............................ 235 6.4C.4.99 Alcohol/contaminants-in-fuel diagnosis ..... 235 6.4C.4.123 Diagnosis of electronic ignition (EI) system ................................................................................... 236

6.4C.5 Repair instructions .......................................... 238 6.4C.5.1 Replacement of intake air temperature sensor ................................................................................... 238 6.4C.5.2 Intake pressure sensor replacement ........... 239 6.4C.5.3 Replacement of electronic throttle valve body assembly .................................................................... 240 6.4C.5.4 Replacement of EGR Valve......................... 241 6.4C.5.5 Replacement of air intake side VVT actuator ................................................................................... 242 6.4C.5.6 Replacement of front oxygen sensor .......... 243 6.4C.5.7 Replacement of back oxygen sensor .......... 244 6.4C.5.8 Replacement of camshaft position sensor .. 245 6.4C.5.9 Replacement of crankshaft position sensor 246 6.4C.5.10 Replacement of coolant temperature sensor ................................................................................... 247 6.4C.5.11 Replacement of knock sensor ................... 248 6.4C.5.12 Replacement of canister solenoid valve.... 249 6.4C.5.13 Replacement of engine module ................ 250 6.4C.5.14 Replacement of electronic accelerator pedal ................................................................................... 251 6.4C.6 Descriptions and operation ............................ 252 6.4C.6.1 General description ..................................... 252 6.4.6.2 Description of engine control module(ECM) .. 252 6.4.6.3 Description of air intake system ..................... 252 6.4C.6.4 Sensor Information/ Switch Description ...... 252 6.4C.6.5 Fuel Rail Description ................................... 253 6.4C.6.6 Fuel Injector Description ............................. 253 6.4C.7 Special tools and equipment .......................... 253


6.4C.1 Specifications(N300/N310) 6.4C.1.1 Fastener Tightening Specifications

Application Specification

Intake pressure temperature sensor 8-12 N. m

Electronic throttle valve 8-12N. m

EGR valve 6-10 N. m

Air inlet side VVT actuator 8-12N. m

Oxygen sensor 40-60N. m

Camshaft Position Sensor 8-12N. m

Crankshaft Position Sensor 8-12N. m

Coolant Temperature Sensor 18-22N. m

Knock Sensor 20-25N. m

Canister Solenoid Valve 8-12N. m

Electronic Accelerator Pedal 9-11N.m


6.4C.2A Circuit Diagram (N300)

6.4C.2.1 Routing diagrams

B

AT

+

1C

109

15A

F6

前氧

传感

器后

氧传

感器

1C

109

5A F4

7C

101

车速转速

轮速

传感

器

点火

线圈

1车

速传

感器

点火

线圈

2点

火线

圈3

点火

线圈

4

19

20

11

22

14

633

C105

C105

C101

10A

F19

32

11

6

2

13

4

2

13

4

12

12

12

12

12

1 2

1 22

2

3

12

3

12

3

12

3

11

32

B-K

3B

-P3

B-N

4B

-F2

B-C

1B

-O4

B-E

2B

-A3

B-L

4B

-K4

B-M

4B

-M3

B-J2

B-Q

3B

-J4B

-E1

A-H

4A

-H2

A-H

1A

-H3

B-K

2B

-D1

B-N

3

ZK

仪表

主控继电器

喷嘴1

喷嘴2

喷嘴3

喷嘴4

碳罐控制阀

进气侧VTT

执行器

白白

白白

白/黄

黄/蓝

红/绿

黄红

/黄

红

紫/黄

绿/白

红/黄

紫/黑

红/黑

红/绿

棕/红

蓝/红

紫/棕

蓝/白

绿/红

红/黑

红/黑

棕/黑

蓝蓝黄

/紫

绿/黑

蓝/灰

橙/棕

绿绿

/蓝

绿/白

绿/红

红紫

/白

绿/橙

G2

01

接地

123 5

新1.2L 发

动机

ECU

黑

1

B-F

1

白/黄

曲轴

位置

传

感器

B-H

3

蓝/黄

1

23

EGR阀4

12

36

A-C

4B

-H2

A-E

1B

-O2

蓝/棕

棕棕

/黄

灰

13AC-06C02001

Cra

nksh

aft

Positio

n

Sensor

Sprayer 4

Sprayer 3

Sprayer 2

Sprayer 1

Back O

xygen

Sensor

Fro

nt O

xyg

en

S

ensor

M

ain

R

ela

y

M

ete

r S

pe

ed

V

eh

icle

S

pe

ed

Ne

w 1

.2 L

En

gin

e E

CU

EG

R V

alv

e

Canister Control Valve

Air Intake Side VVT Actuator

Wh

ee

l sp

eed

sensor

Ignitio

n

Co

il 1

Ignitio

n

Co

il 2

Ignitio

n

Co

il 3

Ignitio

n

Co

il 4

Ve

hic

le S

pe

ed

Se

nso

r

Blu

e/Y

ello

w

Gre

en

/Re

d

Blu

e/W

hite

P

urp

le/B

row

n

Blu

e/R

ed

Pu

rple

/Red

Red

/Gre

en

R

ed

/Bla

ck

Pu

rple

/Bla

ck

Red

/Ye

llow

G

ree

n/W

hite

/Ye

llow

Pu

rple

/Yello

w

Red

/Ye

llow

Red

/Gre

en

Y

ello

w/B

lue

Red

Wh

ite/Y

ello

w

Wh

ite

Wh

ite

Wh

ite

Wh

ite

Re

d/B

lack

Re

d/B

lack

Bro

wn

/Bla

ck

Ye

llow

/Pu

rple

Blu

e

Blu

e

Gre

en

/Bla

ck

Ye

llow

/

Bla

ck

Gro

un

din

g

Blu

e/G

rey

Ora

ng

e/B

row

n

Gre

en

G

ree

n/B

lue

Gre

en

/Wh

ite

Gre

en

/Red

W

hite

/Ye

llow

R

ed

P

urp

le/W

hite

G

ree

n/O

ran

ge

G

rey

Ora

ng

e/Y

ello

w

Bro

wn

B

lue

/Bro

wn


IG

N1

接地

电子

油门

踏板

41

36

34

312

21B

-H1

C105

15A

F12

39

C105

进气

压力

传

感器

爆震

传感

器

水温

传感

器

进气

侧凸

轮轴

位置

传感

器

进气

温度

传感

器电

子节

流阀

控制

模块

黑/白

黑/红

白

12

3

A-F

4A

-B4

A-G

2

棕/红

蓝/黑

红/黄

12

3

绿/黑

蓝黑/绿

13

蓝/黑

黑/白

B-A

2

12

34

56

蓝/白红

绿黑

黑

黄棕/黄

绿/白棕/蓝

黄/棕

白/红

白/蓝

黑

31

21

21

23

54

6

紫/白

灰蓝黑

绿/红

棕/黄

蓝/红

白/黄

红/白

绿/黄棕/白

灰/白

B-A

4B

-B2

B-A

1A

-D3

A-B

2B

-M1

B-D

2B

-D3

B-C

2B

-B1

A-G

4B

-P2

B-P

1A

-D2

A-C

1A

-G1

A-D

4A

-F3

A-F

1A

-E4

A-C

2B

-C3

B-M

2B

-L1

G2

01

新1.2L 发

动机

ECU

14

C105

3C

101

组合

仪表

3

2

13AC-06C02002

Bla

ck/W

hite

Air In

take

Pre

ssure

S

ensor

Knock

Sensor

Ele

ctro

nic

Accele

rato

r P

edal

Wa

ter

Te

mp

era

ture

S

ensor

Instru

ment

Clu

ste

r

Gro

un

din

g

Ne

w 1

.2 L

En

gin

e E

CU

Inta

ke S

ide

Ca

msh

aft

Positio

n

Sensor

Inta

ke

Te

mp

era

ture

S

ensor

Ele

ctro

nic

Thro

ttle

Co

ntro

l Mod

ule

Bla

ck/R

ed

Wh

ite

Bro

wn

/Re

d

Blu

e/B

lack

Re

d/Y

ello

w

Gre

en

/Bla

ck

Bla

ck/G

ree

n

Blu

e

Blu

e/W

hite

Y

ello

w

Gre

en

/Wh

ite Bro

wn

/Blu

e

Bro

wn

/Ye

llow

Y

ello

w/B

row

n

Bla

ck

Wh

ite/B

lue

Wh

ite/R

ed

Bla

ck

Gre

en

R

ed

Blu

e/B

lack

Bla

ck/W

hite

Bla

ck

Gre

y/W

hite

Bro

wn

/Wh

ite

Gre

en

/Ye

llow

R

ed

/Wh

ite

Wh

ite/Y

ello

w

Blu

e/R

ed

Bro

wn

/Ye

llo

w

Gre

en

/Re

d

Blu

e/B

lack

Gre

y

Pu

rple

/White


6.4C.2.2 View of engine control module (ECM) end

A_A1 Blue-black CAN high B_E1 Red-white Wheel speed sensor+

A_A2 White-purple Air conditioning pressure switch B_E2 Red-black Grounding of back oxygen sensor

A_A3 White Clutch switch B_E3 -- --

A_A4 Yellow-white Diagnosis of K-line B_E4 -- --

A_B1 Black-red CAN low B_F1 White-yellow Wheel speed sensor-

A_B2 Black-white Grounding of water temperature

sensor B_F2 Green-white Grounding of front oxygen sensor

A_B3 -- -- B_F3 -- --

A_B4 Blue-black Grounding of intake air pressure

sensor B_F4 -- --

A_C1 Brown-white Signal 2 of throttle position sensor B_G1 Blue-green Air conditioning evaporator

temperature sensor

A_C2 Green-red Grounding of intake air temperature

sensor B_G2 -- --

A_C3 Green-white Brake light switch B_G3 -- --

A_C4 Blue-brown Power supply of EGR position

sensor B_G4 Blue-grey Fuel pump relay

A_D1 Yellow-blue Air-conditioning switch B_H1 Blue-white Power supply of accelerator pedal

2

A_D2 Grey-white Grounding of of throttle position

sensor B_H2 Brown Grounding of EGR position sensor

A_D3 Blue-black Engine water temperature sensor B_H3 Blue-yellow Signal of crankshaft position

sensor

13AC-06C02003


A_D4 Red-white Power supply of throttle position

sensor B_H4 Brown-yellow MIL

A_E1 Brown-yellow EGR position sensor B_J1 -- --

A_E2 Orange-green Service brake switch B_J2 Green-red Grounding of crankshaft position

sensor

A_E3 Grey-red Grounding of air conditioning

evaporator temperature sensor B_J3 Green-white Relay control of fan 2

A_E4 Brown-yellow Intake air temperature sensor B_J4 Purple-white Air inlet side VVT

A_F1 Blue-red Throttle motor— B_K1 -- --

A_F2 Blue-yellow Power-assisted steering switch

（reserved） B_K2 Orange-brown Grounding of vehicle speed signal

A_F3 White-yellow Signal 1 of throttle position sensor B_K3 Red-yellow Main relay

A_F4 Brown-red Power supply of intake air pressure

sensor B_K4 Blue-red Fuel injector 2

A_G1 Green-yellow Throttle motor + B_L1 Purple-white Power supply of intake camshaft

sensor

A_G2 Red-yellow Intake air pressure sensor B_L2 -- --

A_G3 -- -- B_L3 Brown Control of fan relay

A_G4 Black Power grounding 3

B_L4 Brown-red Fuel injector 1

A_H1 Green-blue Ignition coil 3 B_M1 Yellow Power supply of accelerator pedal

1

A_H2 Green-white Ignition coil 2 B_M2 Grey Grounding of air intake camshaft

sensor

A_H3 Green Ignition coil 4 B_M3 Blue-white Oil injection 4

A_H4 Green-red Ignition coil 1 B_M4 Purple-brown Oil injection 3

B_A1 Black-green Knock sensor shield grounding B_N1 -- --

B_A2 White Battery supply B_N2 Black-green Air condition compressor relay

B_A3 Red-green Back oxygen sensor B_N3 Black Engine speed（meter）

B_A4 Green-black Input of knock signal B_N4 Purple-yellow Heating of front oxygen sensor

B_B1 Yellow-brown Signal 2 of accelerator pedal B_O1 -- --

B_B2 Blue Knock grounding B_O2 Grey EGR valve

B_B3 -- -- B_O3 -- --

B_B4 -- -- B_O4 Purple-black Heating of back oxygen sensor

B_C1 Red-yellow Front oxygen sensor B_P1 Black Power grounding 2

B_C2 Blue-brown Grounding of accelerator pedal 2 B_P2 Black Power grounding 1

B_C3 Blue-black Air intake camshaft position sensor B_P3 Yellow Battery power（constant power

supply）

B_C4 -- -- B_P4 Red Battery power（after main relay）

B_D1 Blue-grey Vehicle speed signal B_Q1 -- --

B_D2 brown-yellow Grounding of accelerator pedal 1 B_Q2 -- --

B_D3 Green-white Signal 1 of accelerator pedal B_Q3 Green-orange Canister solenoid valve

B_D4 -- -- B_Q4 -- --


6.4C.2B Circuit diagram (N310)

6.4C.2.1 Circuit diagram

BA

T+

前氧

传感

器后

氧传

感器

车速转速

轮速

传感

器

点火

线圈

1车

速传

感器

点火

线圈

2点

火线

圈3

点火

线圈

4

19

20

11

63

3C

10

5

61

1

2

13

4

2

13

4

1 2

1 2

1 2

1 2

1 2

12

122

2

3

12

3

12

3

12

3

11

32

B-K

3B

-P3

B-N

4B

-F2

B-C

1B

-O4

B-E

2B

-A3

B-L

4B

-K4

B-M

4B

-M3

B-J

2

B-Q

3B

-J4

B-E

1A

-H4

A-H

2A

-H1

A-H

3B

-K2

B-D

1

B-N

3

B-P

4

仪表

喷嘴1

喷嘴2

喷嘴3

喷嘴4

碳罐控制阀

进气侧VTT 执行器

黄红/黄

红

紫/黄

绿/白

红/黄

紫/黑

红/黑

红/绿

棕/红

蓝/红

紫/棕

蓝/白

绿/红

蓝黄/棕

绿/黑

蓝/灰

橙/棕

绿绿/蓝

绿/白

绿/红

红紫/白

绿/橙

G201

发动

机ECU-新

1.2L发

动机

黑

1

B-F

1

白/黄

曲轴

位置

传

感器

B-H

3

蓝/黄

1

23

EGR阀 4

12

36

A-C

4B

-H2

A-E

1B

-O2

蓝/棕

棕棕/黄

灰

C1

05

15

AF

6 白/黄

黄/蓝

红/绿

85

86

30

87

15

AF

12

红/白

1100A

带EPS

不带

EPS

C109

白

白

17

红/黑

10A

F4

5V

13AC-06C02004

Vehic

le

Speed

Sensor

Ye

llo

w/B

row

n

Ignitio

n

Co

il 4

Ignitio

n

Co

il 3

Ignitio

n

Co

il 2

Ignitio

n

Co

il 1

Wh

ee

l sp

eed

sensor

Air Intake Side VVT Actuator

Canister Control Valve

EG

R V

alv

e

Cra

nksh

aft

P

ositio

n

Sensor

Sprayer 4

Sprayer 3

Sprayer 2

Sprayer 1

Back O

xygen

Sensor

Fro

nt

Oxyg

en

S

ensor

M

ete

r S

pe

ed

V

eh

icle

S

pe

ed

Engin

e E

CU

--

New

1.2

L

With

EP

S

With

out

EP

S

Blu

e

Gre

en

/Bla

ck

Ye

llo

w

Re

d/Y

ello

w

Bla

ck

Blu

e/G

rey

Ora

ng

e/B

row

n

Gre

en

G

ree

n/B

lue

Gre

en

/Wh

ite

Gre

en

/Red

W

hite

/Ye

llow

R

ed

P

urp

le/W

hite

Gre

en

/Ora

ng

e

Gre

y

Bro

wn/Y

ello

w

Bro

wn

B

lue

/Bro

wn

Blu

e/Y

ello

w

Gre

en

/Red

B

lue

/Wh

ite

Pu

rple

/Bro

wn

Blu

e/R

ed

Bro

wn

/Red

R

ed

/Gre

en

R

ed

/Bla

ck

Pu

rple

/Bla

ck

Red

/Ye

llow

G

ree

n/W

hite

Pu

rple

/Yello

w

Ye

llo

w/B

lue

Re

d

Re

d/W

hite

Wh

ite

Wh

ite

Wh

ite

/Ye

llow

Re

d/G

ree

n

Re

d/B

lack


IGN

1

电子

油门

踏板

41

36

34

312

21B

-H1

C105

15A

F19

39

C105

进气

压力

传

感器

爆震

传

感器

水温

传感

器

进气

侧凸

轮轴

位置

传感

器

进气

温度

传感

器电

子节

流阀

控制

模块

黑/白

黑/红

白

12

3

A-F

4A

-B4

A-G

2

棕/红

蓝/黑

红/黄

12

3

绿/黑

蓝黑/绿

13

蓝/黑

黑/白

B-A

2

12

34

56

蓝/白红

绿黑

黑

黄棕/黄

绿/白

棕/蓝

黄/棕

白/红

白/蓝

黑

31

21

21

23

54

6

紫/白

灰灰

绿/红

棕/黄

蓝/红

白/黄

红/白

绿/黄

棕/白

灰/白

B-A

4B

-B2

B-A

1A

-D3

A-B

2B

-M1

B-D

2B

-D3

B-C

2B

-B1

A-G

4B

-P2

B-P

1A

-D2

A-C

1A

-G1

A-D

4A

-F3

A-F

1A

-E4

A-C

2B

-C3

B-M

2B

-L1

G2

01

14

C105

组合

仪表

14

2橙

黄/红

发动

机ECU-新

1.2L发动

机

5V5V

5V

5V5V

13AC-06C02005

Engin

e E

CU

-- New

1.2

L

Bla

ck/W

hite

Air In

take

Pre

ssure

S

ensor

K

nock S

ensor

E

lectro

nic

A

ccele

rato

r Ped

al

Wa

ter

Te

mp

era

ture

S

ensor

In

stru

ment

Clu

ste

r

Ele

ctro

nic

Thro

ttle C

ontro

l M

od

ule

Inta

ke

Te

mp

era

ture

S

ensor

Inta

ke S

ide

Ca

msh

aft

Positio

n

Sensor

Bla

ck/R

ed

Bla

ck

Bla

ck/B

row

n

Blu

e/B

lack

Re

d/Y

ello

w

Gre

en

/Bla

ck

Blu

e

Bla

ck/G

ree

n

Blu

e/W

hite

Red

Ye

llow

Gre

en

Bro

wn/Y

ello

w

Gre

en

/Wh

ite

Bro

wn/B

lue

Ye

llow

/Bro

wn

Bla

ck

Wh

ite/R

ed

Bla

ck

Wh

ite/B

lue

Blu

e/B

lack

Ora

ng

e

Bla

ck/W

hite

Ye

llow

/Red

Gre

y/W

hite

B

lack

Bro

wn

/Wh

ite

Gre

en

/Ye

llow

R

ed

/Wh

ite

Wh

ite/Y

ello

w

Blu

e/R

ed

Bro

wn

/Ye

llow

G

ree

n/R

ed

G

rey

Gre

y

Pu

rple

/White


6.4C.2.2 View of engine control module (ECM) end

A_A1 Blue-black CAN high B_E1 Red Wheel speed sensor+

A_A2 White-purple Air conditioning pressure switch B_E2 Red-black

Grounding of back oxygen sensor

A_A3 White Clutch switch B_E3 -- --

A_A4 Yellow-white Diagnosis of K-line B_E4 -- --

A_B1 Red-black CAN low B_F1 White-yellow Wheel speed sensor-

A_B2 Black-white Grounding of water temperature

sensor B_F2 Green-white Grounding of front oxygen sensor

A_B3 -- -- B_F3 -- --

A_B4 Grey-brown Grounding of intake air pressure

sensor B_F4 -- --

A_C1 Brown-white Signal 2 of throttle position sensor B_G1 Green - blue Air conditioning evaporator

temperature sensor

A_C2 Green-red Grounding of intake air temperature

sensor B_G2 -- --

A_C3 Grey Brake light switch B_G3 -- --

A_C4 Blue-brown Power supply of EGR position

sensor B_G4 Blue-grey Fuel pump relay

A_D1 Yellow-blue Air-conditioning switch B_H1 Blue-white Power supply of accelerator pedal

2

A_D2 Grey-white Grounding of of throttle position

sensor B_H2 Black-white Grounding of EGR position sensor

A_D3 Blue-black Engine water temperature sensor B_H3 Blue-yellow Signal of crankshaft position

sensor

A_D4 Red-white Power supply of throttle position

sensor B_H4 Brown-black MIL

13AC-06C02006


A_E1 Brown-yellow EGR position sensor B_J1 -- --

A_E2 Green-orange Service brake switch B_J2 Green-red Grounding of crankshaft position

sensor

A_E3 White-red Grounding of air conditioning

evaporator temperature sensor B_J3 Green-white Relay control of fan 2

A_E4 Green-black Intake air temperature sensor B_J4 Purple-white Air inlet side VVT

A_F1 Blue-red Throttle motor— B_K1 -- --

A_F2 Blue-yellow Power-assisted steering switch

（reserved） B_K2 Yellow-blue Grounding of vehicle speed signal

A_F3 White-yellow Signal 1 of throttle position sensor B_K3 White-purple Main relay

A_F4 Brown-red Power supply of intake air pressure

sensor B_K4 Blue-red Fuel injector 2

A_G1 Green-yellow Throttle motor + B_L1 Brown-white Power supply of intake camshaft

sensor

A_G2 Yellow-white Intake air pressure sensor B_L2 Green-purple Grounding of oil level sensor

A_G3 -- -- B_L3 Brown Control of fan relay

A_G4 Black Power grounding 3

B_L4 Brown-red Fuel injector 1

A_H1 Green-blue Ignition coil 3 B_M1 Yellow Power supply of accelerator pedal

1

A_H2 Green-white Ignition coil 2 B_M2 Grey Grounding of air intake camshaft

sensor

A_H3 Green Ignition coil 4 B_M3 Grey-green Oil injection 4

A_H4 Green-red Ignition coil 1 B_M4 Purple-brown Oil injection 3

B_A1 Black-green Knock sensor shield grounding B_N1 -- --

B_A2 White Battery supply B_N2 Black-green Air condition compressor relay

B_A3 Red-green Back oxygen sensor B_N3 Green-black Engine speed（meter）

B_A4 Green-black Input of knock signal B_N4 Purple-yellow Heating of front oxygen sensor

B_B1 Yellow-brown Signal 2 of accelerator pedal B_O1 -- --

B_B2 Blue Knock grounding B_O2 Yellow-purple EGR valve

B_B3 Red-green Wheel speed signal B_O3 -- --

B_B4 Brown-blue Oil level sensor B_O4 Black-yellow Heating of back oxygen sensor

B_C1 Red-yellow Front oxygen sensor B_P1 Black Power grounding 2

B_C2 Blue-brown Grounding of accelerator pedal 2 B_P2 Black Power grounding 1

B_C3 Blue-black Air intake camshaft position sensor B_P3 Yellow Battery power（constant power

supply）

B_C4 -- -- B_P4 Red Battery power（after main relay）

B_D1 Blue-grey Vehicle speed signal B_Q1 -- --

B_D2 Green-orange Grounding of accelerator pedal 1 B_Q2 -- --

B_D3 Green Grounding of accelerator pedal 1 B_Q3 Green-orange Canister solenoid valve

B_D4 -- -- B_Q4 -- --


6.4C.3A Description of engine control

system connector (N300)

6.4C.3.1 Electronic throttle

13AC-06C03001

Line No. Line color Function

2 Red/white Throttle position sensor

power

4 Brown/white Throttle position sensor

signal 2

6 Grey/white Throttle position sensor

grounding

1 White/yellow Throttle position sensor

signal 1

3 Red/yellow Throttle motor+

5 Blue/red Throttle motor-

6.4C.3.2 Water temperature sensor

2 31

13AC-06C03002


1 Blue/black Water temperature

sensor signal

2 Orange Connected to the

meter

3 Black/white Water temperature

sensor grounding

6.4C.3.3 Intake pressure sensor

1 2 3

13AC-06C03003


1 Brown/red Power supply of intake

pressure sensor

2 Blue/black Grounding of intake

pressure sensor

3 Red/yellow Intake pressure sensor

6.4C.3.4 Canister solenoid valve

1 2

13AC-06C03004


1 Red/white Power of throttle

posistion sensor

2 Brown/white Signal 2 of throttle

posistion sensor

3

6

2

54

1


6.4C.3.5 Back oxygen sensor

4

21

3

13AC-06C03005


1 Red/green Oxygen sensor signal

2 Red Heating power

3 Red/black Oxygen sensor

grounding

4 Purple/black Heating control terminal

6.4C.3.6 Front oxygen sensor

6.4C.3.7 Crankshaft position sensor

6.4C.3.8 Intake side camshaft position

sensor

2 31

13AC-06C03008


1 Grey Sensor grounding

2 Blue/black Sensor signal

3 Purple/white Sensor power

4

21

3

13AC-06C03006


1 Red/yellow Oxygen sensor signal

2 Red Heating power

3 Green/white Oxygen sensor

grounding

4 Purple/yellow Heating control terminal

1 2 3

13AC-06C03007


1 Red Power supply

2 Blue/yellow Sensor signal

3 Green/red Sensor grounding


6.4C.3.9 EGR valve

2

5 6

3

4

1

13AC-06C03009


1 Blue/brown Power supply of EGR

position sensor

2 Black/white Grounding of EGR

position sensor

3 Brown/yellow Signal of EGR

position sensor

4 Red EG power supply

5 — —

6 Grey EGR control terminal

6.4C.3.10 Intake air temperature sensor

1 2

13AC-06C03010



2 Brown/yellow Sensor signal

6.4C.3.11 Vehicle speed sensor

1 2 3

13AC-06C030011


1 Red Sensor power

2 Orange/brown Sensor grounding

3 Blue/grey Sensor signal

6.4C.3.12 Knock sensor

1 2 3

13AC-06C03012


1 Green/black Sensor signal

2 Blue Sensor grounding

3 Black/green Shield ground


6.4C.3.13 Intake side VVT control

1 2

13AC-06C03013


1 Red Solenoid valve power

2 Purple/white Solenoid valve

control terminal

6.4C.3.14 Air conditioning evaporator

temperature sensor

1 2

13AC-06C03014


1 Yellow/blue Temperature sensing

end (signal)

2 Yellow Temperature sensing

end (grounding)

6.4C.3.15 Ignition coil 1

1 2 3

13AC-06C03015


1 Black Grounding

2 Red Power supply of

ignition coil

3 Green/red Control terminal of

ignition coil


1 2 3

13AC-06C03016


1 Black Grounding


ignition coil

3 Green/white Control terminal of

ignition coil



1 2 3

13AC-06C03017


1 Black Grounding


ignition coil

3 Green-blue Control terminal of

ignition coil


1 2 3

13AC-06C03018


1 Black Grounding


ignition coil

3 Green Control terminal of

ignition coil

6.4C.3.19 Fuel injector 1

1 2

13AC-06C03019


1 Red Power supply of fuel

injector

2 Brown/red Control terminal of

fuel injectorl


1 2

13AC-06C03020



injector

2 Blue/red Control terminal of

fuel injector



1 2

13AC-06C03021



injector

2 Purple/brown Control terminal of

fuel injector


1 2

13AC-06C03022



injector

2 Blue/yellow Control terminal of

fuel injector

6.4C.3.23 Fuel pump

1 2

3 4

13AC-06C03023


1 Black Grounding of fuel

pump

2 Black Grounding of oil level

signal

3 Yellow/blue

Positive pole of

power supply of fuel

pump

4 Yellow Oil level signal

6.4C.3.24 Electronic accelerator pedal

1 2 3 4 5 6

13AC-06C03024


1 Red E-accelerator pedal

power 2

2 Green E-accelerator pedal

power 1

3 Black E- accelerator pedal

grounding 1

4 White/ red E- accelerator pedal

signal 1

5 Black E- accelerator pedal

grounding 2

6 White/blue E- accelerator pedal

signal 2


6.4C.3.25 Electronic clutch switch

1

2

13AC-06C03025


1 Red Signal terminal

2 Black Grounding

6.4C. 3.26 Wheel speed sensor

6.4C.3.27 Service brake switch

1 2

3 4

12AC-0604030


1 black Grounding

2 Green/black Power terminal

3 White Brake signal

(normally closed)

4 Green Brake signal

(normally open)

21

13AC-06C03026


1 Red/white Wheel speed sensor+

2 White/yellow Wheel speed sensor -


6.4C.3B Instruction of engine control system connector (N310)

6.4C.3.1 Electronic throttle valve

6

5

4

31

2

13AC-06C03028


1 White/yellow Throttle position sensor signal 1

2 Red/white Power supply of

throttle position sensor

3 Green/yellow Throttle motor +

4 Brown/white Throttle position sensor signal 2

5 Blue/red Throttle motor -

6 Grey/white Grounding of throttle

position sensor

6.4C.3.2 Water temperature sensor

2 31

13AC-06C03029


1 Blue/black Water temperature

sensor signal

2 Orange/white Connected to the

meter

3 Black/white Grounding of water temperature sensor

6.4C.3.3 Intake air pressure sensor

6.4C.3.4 Canister solenoid valve

1 2 3

13AC-06C03030


1 Brown/red Power supply of intake air

pressure sensor

2 Grey/brown Grounding of intake air

pressure sensor

3 Yellow/white Intake air pressure sensor

1 2

13AC-06C03031


1 Red Power supply of throttle position

sensor

2 Green/or

ange Throttle position sensor signal 2


6.4C.3.5 Back oxygen sensor

4

21

3

13AC-06C03032


1 Red/green Oxygen sensor signal

2 Red Heating power supply

3 Red/black Grounding of oxygen

sensor

4 Black/yello

w Heating control

terminal

6.4C.3.6 Front oxygen sensor

4

21

3

13AC-06C03033


1 Red/yellow Oxygen sensor

signal

2 Red Heating power

supply

3 Green/white Grounding of oxygen

sensor signal

4 Purple/yellow Heating control

terminal

6.4C.3.7 Crankshaft position sensor

1 2 3

13AC-06C03034


1 Red Power supply

2 Blue/yellow Sensor signal


6.4C.3.8 Air inlet side camshaft

position sensor

2 31

13AC-06C03035


1 Grey Sensor grounding

2 Blue/black Sensor signal

3 Purple/white Power supply of

sensor


6.4C.3.9 EGR valve

2

5 6

3

4

1

13AC-06C03036


1 Blue/brown Power supply of

EGR position sensor

2 Black/white Grounding of EGR

position sensor

3 Brown/yellow EGR position sensor signal

4 Red EG power supply

5 — —

6 Yellow/purple EGR control

terminal

6.4C.3.10 Intake air temperature

sensor

1 2

13AC-06C03037




6.4C.3.11 Vehicle speed sensor

1 2 3

13AC-06C03038



sensor

2 Orange/blue Grounding of

sensor

3 Blue/grey Sensor signal

6.4C.3.12 Knock sensor

1 2 3

13AC-06C03039



2 Blue Grounding of

sensor

3 Black/green Shield grounding


6.4C.3.13 Air inlet side VVT control

1 2

13AC-06C03040


1 Red Power supply of solenoid valve

2 Purple/white Control terminal of

solenoid valve

6.4C.3.14 Air conditioning

evaporator temperature sensor

1 2

13AC-06C03041


1 Yellow/blue Temperature sensing

end (signal)

2 Yellow Temperature sensing

end (grounding)

6.4C.3.15 Ignition coil1 1

3 2 1

13AC-06C03042


3 Black Grounding


ignition coil

1 Green/red Control terminal of

ignition coil


3 2 1

13AC-06C03043


3 Black Grounding


ignition coil

1 Green/white Control terminal of

ignition coil



1 2 3

13AC-06C03044


1 Black Grounding


ignition coil

3 Green/blue Control terminal of ignition coil


1 2 3

13AC-06C03045


1 Black Grounding


ignition coil

3 Green Control terminal of ignition coil


1 2

13AC-06C03046


1 Red Power supply of fuel injector

2 Brown/red Control

terminal of fuel injector


1 2

13AC-06C03047


1 Red Power supply of fuel injector

2 Blue/red Control

terminal of fuel injector



1 2

13AC-06C03048



fuel injector

2 Purple/brown Control terminal of fuel injector


1 2

13AC-06C03049



fuel injector

2 Grey/green Control terminal of fuel injector

6.4C. 3.23 Fuel pump

1 2

3 4

13AC-06C03050


1 Black Grounding of fuel

pump

2 Black Grounding of oil

level signal

3 Yellow/blue Positive pole of power supply of

fuel pump

4 Yellow Oil level signal

6.4C. 3.24 Electronic accelerator

pedal

1 2 3 4 5 6

13AC-06C03051


1 Red E-accelerator pedal

power 2

2 Green E-accelerator pedal

power 1

3 Black/blue E- accelerator

pedal grounding 1

4 White/red E- accelerator

pedal signal 1

5 Black/red E- accelerator

pedal grounding 2

6 White/blue E- accelerator

pedal signal 2


6.4C. 3.26 Wheel speed sensor

21

13AC-06C03052


1 Red/white Wheel speed

sensor +

2 White/yellow Wheel speed

sensor -

6.4C. 3.27 Service brake switch

1 2

3 4

13AC-06C03053


1 Black Grounding

2 Green/black Power supply

end

3 White Brake signal

(normally closed)

4 Green Brake signal

(normally open)


6.4C.4 Diagnostic information and procedures

6.4C.4.1 Diagnostic starting point

Begin the system diagnosis with a check of powertrain on-board diagnostic (OBD) system. The check of powertrain

OBD system will provide the following information:

● Identification of instruction system control modules.

● Communication of the control modules is made through the serial data circuit.

● Identification of all the stored diagnostic trouble codes (DTCs) and their status.

By checking the powertrain OBD system, identify the correct procedure for diagnosing the system and where the

procedure is located.

6.4C.4.2 Check of powertrain on-board diagnostic (OBD) system

Circuit description

The check of powertrain on-board diagnostic (OBD) system must be the starting point for any drivability complaint

diagnosis. Before using this procedure, you should perform a careful visual and physical check of the powertrain control

module (PCM) and engine grounds for being clean and tight. The check of powertrain on-board diagnostic (OBD)

system is an organized approach to identifying a problem created by an electronic engine control system malfunction.

MIL operation:

The Malfunction indicating lamp (MIL) is located on the instrument panel (CHECK ENGINE) or (SERVICE ENGINE

SOON). The MIL performs the following functions:

● It informs the driver that a problem has occurred and that the vehicle should be taken for service as soon as

possible.

● As a system check, the MIL will illuminate with the ignition switch ON and the engine not running. When the engine

is started, the MIL will turn OFF. If the MIL remains ON, the self- diagnostic system has detected a problem. If the

problem goes away, the MIL will turn OFF in most cases, but a diagnostic trouble code will remain stored.

● If the MIL is illuminated, then the engine stalls, the MIL will remain Illuminated so long as the ignition switch is ON.

● If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF,

then ON.

Perform The check of powertrain on-board diagnostic (OBD) system first, when the following conditions are present:

The MIL does not turn ON when the ignition switch is turned to the RUN position.

The MIL remains ON while the engine is running.

You suspect a drivability problem.

Diagnostic aids:

An intermittent problem may be caused by:

Poor connection

Rubbed through wire insulation

A wire broken inside the insulation

Check for poor connections or a damaged harness. Inspect the PCM harness and connectors for:

Improper mating

Broken locks

Improperly formed or damaged terminals

Poor terminal-to-wire connection

Damaged harness


Test description:

The numbers below refer to the step numbers on the diagnostic table:

1. The MIL should be ON steady with the key ON and the engine OFF. If not, the "MIL" should be used to isolate the

malfunction.

2. This test ensures that the PCM is capable of transmitting Class 2 serial data to the data link connector (DLC) and

that the Class 2 data circuit is not open or shorted. If a problem is encountered and a malfunctioning scan tool is

suspected, try the scan tool on another vehicle to verify operation. If a DLC problem exists, the DLC diagnosis table

should be used to diagnose the condition.

3. Refer to DTC List for a complete list of DTCs supported by this vehicle application. If multiple DTCs are stored,

diagnose each DTC according to the following priority:

PCM error DTCs

System voltage DTCs

Component level DTCs (switches, sensor range/performance, sensor high voltage, sensor low voltage, ODMs,

etc…)

System level DTCs (idle control system, HO2S response)

A scan tool parameter which is not within the typical range may help to isolate the area which is causing the problem.


Check of powertrain on-board diagnostic (OBD) system

Step Action Value (s) Yes No

1.

Important:

Check for applicable service bulletins before

proceeding with the diagnosis.

Do not turn OFF the ignition switch when performing

this diagnostic table.

Do not perform this test if no drivability condition

exists.

Unless instructed, do not clear any DTCs.

1. Turn ON the ignition device with the engine OFF.

2. Observe the MIL.

Is the MIL illuminated?

- Go to Step 2 Check the MIL

inoperative

2.

1. Turn off the ignition switch.

2. Install a scan tool.

3. Turn on the ignition device without the engine

running.

4. Display the ECM data with the scan tool.

Does the scan tool display ECM data?

- Go to Step 3 Check the DLC

3. Start the engine.

Did the engine start? - Go to Step 4

Check for the

engine starting

4. Did the engine start and continue to run? - Go to Step 5

Check for the

engine starting

but not running

5.

Important:

If the scan tool indicates any DTCs set, record the

Freeze Frame/Failure Records.

Use the scan tool in order to display DTCs.

Does the scan tool indicate any DTCs set?

- Go to applicable

DTC table Go to Step 6

6.

With a scan tool, compare the ECM data to the scan tool

data List. Does the scan tool indicate ECM values are

equal to or within the typical values?

- System OK Go to

"Symptom"


6.4C.4.3 Type definitions of diagnostic trouble code (DTC)

P0645 A/C compressor relay circuit open

P0646 A/C compressor relay circuit short to earth

P0647 A/C compressor relay circuit short to power

P0325 Knock sensor fault (signal pickup fault)

P0325 Knock sensor fault (signal absolute value fault)

P0504 Inappropriate brake light and brake signal relativity

P0341 Intake camshaft position sensor signal exceeding the cycle

P0341 Inappropriate intake camshaft position sensor signal

P0016 Inappropriate crankshaft position and intake camshaft

position relativity

P0011 Position offset of intake camshaft at steady condition

P0341 Inappropriate intake camshaft position sync

P0340 Inappropriate intake camshaft position sync signal

P0420 Low catalyst conversion efficiency

P0336 Crankshaft sensor having no signal

P0336 Inappropriate crankshaft sensor signal

P0336 Crankshaft sensor signal falling out

P0373 Inappropriate signal of crankshaft teeth

P0373 Inappropriate signal cycle of crankshaft teeth

P0691 Cooling fan relay 1 circuit open

P0691 Cooling fan relay 1 circuit short to earth

P0692 Cooling fan relay 1 circuit short to power

P0693 Cooling fan relay 2 circuit open

P0693 Cooling fan relay 2 circuit short to earth

P0694 Cooling fan relay 2 circuit short to power

P2413 EGR valve position self-learning error

P0488 EGR valve position control error

P0487 EGR valve driver open-circuit

P0489 EGR valve driver short to earth

P0490 EGR valve driver short to power

P0444 Canister control valve circuit open

P0458 Canister control valve circuit short to earth

P0459 Canister control valve circuit short to power

P0113 Intake temperature sensor circuit short to power

P0112 Intake temperature sensor circuit short to earth

P2100 ETC electrical failure open circuit

P2101 ETC over-temperature protection

P2100 ETC electrical failure short circuit

P0638 Inappropriate ETC_1 position controller output signal

P0639 Inappropriate ETC_2 position controller output signal

P0133 Slow convertion time response of upstream oxygen sensor

P0171 Fuel system diagnosis-too lean

P0172 Fuel system diagnosis-too rich

P0351 Cylinder 1 ignition coil open





P2300 Cylinder 1 ignition coil short to earth




P2301 Cylinder 1 ignition coil short to power




P0506 Too low speed by idle speed control

P0507 Too high speed by idle speed control

P0201 Cylinder 1 fuel injector circuit open




P0261 Cylinder 1 fuel injector circuit short to earth




P0262 Cylinder 1 fuel injector circuit short to power




P2096 Fuel Post O2 correction too dilute

P2097 Fuel Post O2 correction too dense

P0037 Downstream oxygen sensor heater control circuit open

P0037 Downstream oxygen sensor heater control circuit short to

earth

P0038 Downstream oxygen sensor heater control circuit short to

power

P0031 Upstream oxygen sensor heater control circuit open

P0031 Upstream oxygen sensor heater control circuit short to

earth

P0032 Upstream oxygen sensor heater control circuit short to

power

P0106 Imappropriate intake manifold pressure sensor signal

P0107 Intake manifold pressure sensor circuit short to earth

P0108 Intake manifold pressure sensor circuit short to power

P0606 Processor communication error

P0650 Malfunction indicating lamp circuit open

P0650 Malfunction indicating lamp circuit short to earth

P0650 Malfunction indicating lamp circuit short to power

P0301 Misfire 0 (cylinder 1)




P0300 Repeated misfire

P060A Monitoring failure

P060C Monitoring failure of main controller


P061C Monitoring failure of engine rotate speed limits

P0141 Downstream oxygen sensor heating circuit unreasonable

P0135 Upstream oxygen sensor heating circuit unreasonable

P0136 Downstream oxygen sensor circuit open

P0130 Upstream oxygen sensor circuit open

P2120 Accelerator pedal disconnection diagnosis

P2299 Contradictory positions of the break and the accelerator

pedal

P2123 Overtension of accelerator position sensor 1

P2128 Overtension of accelerator position sensor 2

P2122 Low voltage of accelerator position sensor 1

P2127 Low voltage of accelerator position sensor 2

P2138 Inappropriate voltage relativity of accelarator position

sensor 1/2

P0134 Upstream oxygen sensor uncompleted

P0325 Knock sensor fault (signal absolute value fault)

P0627 Fuel pump relay circuit open

P0628 Fuel pump relay circuit short to earth

P0629 Fuel pump relay circuit short to power

P0685 Main relay circuit break to earth

P0686 Main relay circuit short to earth

P0687 Main relay circuit short to power

P0137 Downstream oxygen sensor circuit short to earth

P0131 Upstream oxygen sensor circuit short to earth

P0138 Downstream oxygen sensor circuit short to power

P0132 Upstream oxygen sensor circuit short to power

P0315 Flywheel self-adaption cycle time at limit state

P0075 Intake VVT solenoid circuit open

P0076 Intake VVT solenoid short to earth

P0077 Intake VVT solenoid short to power

P0537 Air conditioning evaporator temperature sensor short to

earth

P0538 Air conditioning evaporator temperature sensor circuit

short to power or open

P0117 Engine coolant temperature sensor circuit short to earth

P0118 Engine coolant temperature sensor circuit short to power

or open

P0119 Engine coolant temperature sensor signal gradient failure

P0016 Intake camshaft position offset

P2176 TPS unable to reach the lower cutoff point

P2176 Lower cutoff point self-learning out of limits

P2176 Lower cutoff point self learning spring failure

P2176 Self learning conditions unattainable

P2176 Throttle limping position self learning value out of scope

P2176 TPS self learning unable to reach the upper cutoff point

P2176 Upper cutoff point self learning spring failure

P2118 Over deviation of throttle position signal

P0121 Inappropriate signal of throttle position sensor 1

P0221 Inappropriate signal of throttle position sensor 2


P2135 Inappropriate voltage relativity of throttle position sensor

1/2

P061A Monitoring failure of rationality of torque demanded and

actual torque

P061B Actual or demanded torque exceeding the allowed

P0643 Overtension of sensor supply voltage 1 circuit

P0642 Low voltage of sensor supply voltage 1 circuit

P0653 Overtension of sensor supply voltage 2 circuit


P0406 EGR valve position signal high

P0405 EGR valve position signal low

P0563 High power supply voltage

P0562 Low power supply voltage

P0123 Overtension of throttle position sensor 1

P0122 Low voltage of throttle position sensor 1

P0223 Overtension of throttle position sensor 2

P0222 Low voltage of throttle position sensor 2

P0500 Inappropriate vehicle speed sensor signal

P2158 Inappropriate wheel speed sensor signal


6.4C.4.4 Inoperative Malfunction indicating lamp (MIL)

Refer to engine controls schematics: engine power, grounds, MIL and data link.

Circuit description

There should be a steady Malfunction indicating lamp (MIL) with the ignition ON and the engine not running. Ignition

feed voltage is supplied directly to the MIL. The Powertrain Control Module (ECM) turns the MIL ON by grounding the

MIL control circuit. No MIL with the key ON, engine not running and the MIL DTC set suggests an open in the MIL

control circuit.

MIL operation

The MIL is located on the instrument panel (CHECK ENGINE) or (SERVICE ENGINE SOON).

The MIL performs the following functions:

It informs the driver that a problem has occurred and that the vehicle should be taken for service as soon as

possible.

As a system check, the MIL will illuminate with the ignition switch ON and the engine not running. When the engine

is started, the MIL will turn OFF. If the MIL remains ON, the self- diagnostic system has detected a problem. If the

problem goes away, the MIL will turn OFF in most cases, but a diagnostic trouble code will remain stored.

If the MIL is illuminated, then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON.

If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF,

then ON.

Perform the check of powertrain on-board diagnostic (OBD) system first, when the following conditions are present:

1. The MIL does not turn ON when the ignition switch is turned to the RUN position.

2. The MIL remains ON while the engine is running.

3. You suspect a drivability problem.

Diagnostic aids

An intermittent problem may be caused by a poor connection, rubbed-through wire insulation, or a wire that is broken

inside the insulation.

Check wiring harness and connectors of the power system control module for the following phenomena:

Improper mating

Broken locks



Damaged harness

If the engine runs OK, check for a malfunctioning MIL, an open in the MIL control circuit, or an open in the

instrument cluster ignition feed.

If the engine cranks but will not run, check for an open PCM ignition, battery feed, or a poor PCM to engine ground.

Test description

The numbers below refer to the step numbers located in the diagnostic table.

1. If the MIL DTC is set, the MIL Control Circuit table will better diagnose the condition.

2. Using a test lamp connected to B+, probe each of the PCM ground terminals to ensure that a good ground is

present.


MIL inoperative

Step Action Yes No

1 Did you perform the check of powertrain on-board diagnostic

(OBD) system? Go to Step 2

Go to "Check of

powertrain

on-board diagnostic

(OBD) system"

2 Does the scan tool indicate any MIL DTCs set? Go to DTC P0650

MIL control circuit Go to Step 3

3 Inspect the PCM feed fuses. Are the fuses OK? Go to Step 4 Go to Step 9

4

1. Disconnect the ignition switch.

2. Disconnect the PCM.

3. Turn on the ignition.

4. Probe the PCM ignition feed circuit using a test lamp that is

connected to a good ground.

Did the test lamp come ON?

Go to Step 5 Go to Step 8

5

Probe the PCM battery feed circuit using a test lamp that is


Did the test lamp come ON?


6

Test for faulty PCM grounds or poor PCM ground connections.

Refer to 'Testing for intermittent and poor connections" in "Wiring

systems".

Did you find and correct the condition?

Go to "Check of

powertrain on-board

diagnostic

(OBD) system"

Go to Step 7

7 Is the replacement complete?

Go to "Check of

powertrain on-board

diagnostic

(OBD) system"

-

8

Locate and repair open in PCM battery feed circuit or the PCM

ignition feed circuit. Refer to "Wiring repairs" in "Wiring systems".

Is the service complete?

Go to "Check of

powertrain on-board

diagnostic

(OBD) system"

-

9

Locate and repair short to ground in PCM ignition feed circuit or

the PCM battery feed circuit. Refer to "Wiring repairs" in "Wiring

systems".


Go to "Check of

powertrain on-board

diagnostic

(OBD) system"

-


6.4C.4.5 Diagnosis of data link connector

Refer to engine controls schematics: power, grounds, MIL and data link connector.

Circuit description

The Class 2 serial data circuit to the data link connector (DLC) allows bi-directional communication between the PCM

and the scan tool. If communication between the scan tool and the powertrain control module (PCM) cannot be

established, the procedure in the DLC diagnosis table should be used to diagnose the condition.

Diagnostic aids

Inspect for the following Items:

For the PCM to establish communication with the scan tool, system voltage must be between 9.0 and 16.0 volts. If

system voltage is not within this range, refer to the "Check of diagnostic system - starting and charging" in "Engine

electrical system".

Ensure that the correct application (model year, carline, VIN code) has been selected on the scan tool. If

communication still cannot be established, try the scan tool on another vehicle to ensure that the scan tool or

cables are not the cause of the condition. An intermittent may be caused by a poor connection, rubbed through wire

insulation or a wire broken inside the insulation.

Check for poor connections or damaged wiring harness.

Check wiring harness and connectors of the power system control module for the following phenomena:

Improper mating

Broken locks



Damaged harness

Use a corresponding mating terminal to check for proper terminal tension.


Diagnosis of data link connector


1 Did you perform the check of powertrain on-board

diagnostic (OBD) system? - Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

2

1. Turn ON the ignition, with the engine OFF.

2. Connect a test lamp between the battery feed circuit

of the data link connector (DLC) and the ground

circuit of the DLC.

Is the test lamp on?

- Go to Step 4 Go to Step 3

3

Connect a test lamp between the battery feed circuit of

the DLC and chassis ground.

Is the test lamp on?


4

Turn ON the ignition, with the engine OFF. Connect a

DMM between the Class 2 serial data circuit of the DLC

and a good ground. Does the voltage equal the specified

value?

0.0 V Go to Step 5 Go to Step 7

5

1. Disconnect the ignition switch.

2. Disconnect the PCM.


Connect the DMM between the Class 2 serial data circuit

of the DLC and battery positive voltage.


6

1. Repair the open in the Class II serial data circuit.

2. Refer to "Wiring repairs" in "Wiring systems".


-

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

Go to Step 11

7

1. Repair the short to voltage in the Class 2 serial data

circuit.

2. Refer to "Wiring repairs" in "Wiring systems".


-

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

Go to Step 11

8

Repair the short to ground in the Class 2 serial data

circuit. Refer to "Wiring repairs" in "Wiring systems".


-

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

-

9

Repair the open circuit in the DLC ground circuit. Refer to

"Wiring repairs" in "Wiring systems".


-

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

-

10

Repair open or short to ground in the DLC battery feed

circuit. Replace the fuse, if necessary. Refer to "Wiring

repairs" in "Wiring systems".


-

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

-

11 Is the service complete? -

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

-


6.4C.4.6 DTC P0130 Upstream oxygen sensor circuit open

Circuit description

The 4 pins connected to the oxygen sensor (short as HO2S) respectively are heater power terminal (12V), sensor

terminal (ECU terminal pin B_F2), signal terminal (ECU pin B_C1) and heater control terminal (ECU terminal pin B_N4).

This system has utilized the heated oxygen sensor which has the heating circuit in addition to the oxygen sensor signal

circuit. Oxygen sensor inputs oxygen sensor voltage through the ECU pin B_C1. The oxygen sensor signal voltage will

vary between 0V and 1V when the oxygen sensor is in good operating condition. 450mV is the reference voltage. Higher

oxygen sensor voltage than it indicates the gas mixture is too rich (λ<1) while lower voltage indicates too lean the gas

mixture (λ>1). When λ closed loop control works, ECU will monitor the oxygen sensor signal and adjust the amount of

fuel injected according to the gas mixture concentration sent by the signal. DTC P0130 will be set up on conditions that

the signal is always suppressed in the range lower than the reference voltage.

Conditions for setting trouble code

Internal resistance of front oxygen sensor ≥50000 Ohm.

Minimum delay time of open-circuit fault diagnosis of front oxygen sensor＞10S

Actions taken when trouble code is set

It will enter into failure memory immediately a malfunction arises.

Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 2 consecutive driving cycles.

Conditions for turning off the MIL/clearing DTC

If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.

When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared.

Fault code can be cleared with a malfunction diagnosis instrument.

Aids for diagnosis

Check for the following situations:

Heated oxygen sensor wire-imappropriate wiring of sensor lead wire and in contact with the exhaust system

Bad grounding of ECU and engine body.

Fuel pressure- if it’s too low, the system will get lean. ECU can compensate a little to the decrease. But if fuel

pressure is too low, set up DTC P0130.

Vacuum leak- check for disconnected or damaged vacuum hose and vacuum leaks of intake manifold, throttle body

and crankcase vent system.

Exhaust leak-it may cause external air sucked in through the heated oxygen sensor exhaust stream and make the

system seeming lean. Check for exhaust leak which may cause false indication of too lean system.

Nonuniform spray of fuel spray nozzle shows the need to clean the nozzle.

Fuel pollution- water, even in the smallest quantity, will be transported to the fuel spray nozzle. Lean exhaust

indication caused by water. Excessive alcohol in the fuel may also lead to this phenomenon.


P0130 Upstream oxygen sensor circuit open


1. Did you perform the check of powertrain on-board

diagnostic system? - Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2.


2. Operate the vehicle within the "Conditions for

running the DTC".

3. Use the scan tool to monitor the trouble code

information.

Does the scan tool indicate that the DTC P0130 is

current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

Inspect and test for the following:

a. Leakage of exhaust pipe.

b. Proper installation of sensor.

c. Damage of wiring harness.



4.

1. Turn OFF the ignition.

2. Disconnect the HO2S connector.

3. Turn ON the ignition.

4. Observe the O2S voltage parameter with a scan tool.

Does the scan tool indicate the HO2S voltage is the

specified value?

410mV Go to Step 5 Go to Step 6

5.

Check the HO2S signal circuit for a short to ground or

short to sensor ground.



6. Replace the HO2S.

Is the replacement complete? - Go to Step 8 -

7. Replace the ECU.


8.

1. Clear the DTC.


running the DTC". Use the scan tool to monitor the

trouble information.


current?

- Go to Step 3 System OK


6.4C.4.7 DTC P0136 Downstream oxygen sensor circuit open

Circuit description


terminal (ECU terminal pin B_ F2), signal terminal (ECU pin B_ C1) and heater control terminal (ECU terminal pin B_

N4).


circuit. Oxugen sensor inputs oxygen sensor voltage through the ECU pin B_F4. The oxygen sensor signal voltage will



mixture (λ>1). When λclosed loop control works, ECU will monitor the oxygen sensor signal and adjust the amount of




Internal resistance of back oxygen sensor ≥50000 Ohm

Delay time of activating fault diagnosis ≥125S

Actions taken when diagnostic trouble code is set




● If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.

● When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared.

● Fault code can be cleared with a malfunction diagnosis instrument.

Aids for diagnosis


Heated oxygen sensor wire-imappropriate wiring of sensor lead wire and in contact with the exhaust system

Bad grounding of ECU and engine body.

Fuel pressure- if it’s too low, the system will get lean. ECU can compensate a little to the decrease. But if fuel

pressure is too low, set up DTC P0136.

Vacuum leak- check for disconnected or damaged vacuum hose and vacuum leaks of intake manifold, throttle body

and crankcase vent system.

Exhaust leak-it may cause external air sucked in through the heated oxygen sensor exhaust stream and make the

system seeming lean. Check for exhaust leak which may cause false indication of too lean system.

Nonuniform spray of fuel spray nozzle shows the need to clean the nozzle.

Fuel pollution- water, even in the smallest quantity, will be transported to the fuel spray nozzle. Lean exhaust

indication caused by water. Excessive alcohol in the fuel may also lead to this phenomenon.


DTC P0136 Downstream oxygen sensor circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2.



running the DTC".


information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

Inspect and test for the following:

1. Leakage of exhaust pipe.

2. Proper installation of sensor.

3. Damage of wiring harness.



4.




4. Observe the O2S voltage parameter with a scan tool.

Does the scan tool indicate the HO2S voltage is the

specified value?

410mV Go to Step 5 Go to Step 6

5.

Check the HO2S signal circuit for a short to ground or

short to sensor ground.





7. Replace the ECU.


8.

1. Clear the DTC.





current?



6.4C.4.8 DTC P0131 Upstream oxygen sensor circuit short to earth

Circuit description


grounding (ECU pin B_F2), signal terminal (ECU terminal pin B_C1) and heater control terminal (ECU terminal pin

B_N4).









Internal resistance of front oxygen sensor < 10 Ohm.

Time counter of short-to-earth diagnosis of front oxygen sensor ≥ 20S

Air flow integrated value after the canister is closed ≥ 30g

Minimum delay time of short-to-earth diagnosis of front oxygen sensor > 2.0S









DTC P0131 Upstream oxygen sensor circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2.

1. Operate the vehicle within the conditions for setting

parameters.

2. With a scan tool, observe the HO2S voltage

parameter.

Is the HO2S voltage at the specified value?

410 mV Go to Step 4 Go to Step 3

3.

Operate the vehicle within the Failure Records

conditions.

Does the scan tool indicate this DTC failed this ignition?

- Go to Step 4

Go to

"Diagnostic

aids"

4.

1. Disconnect the HO2S.


Does the scan tool indicate that the HO2S voltage is at

the specified value?


5.

Test the HO2S signal circuit for a short to ground or a

short to sensor ground. Refer to "Circuit testing" and

"Wiring repairs" in "Wiring

systems".



6. Is the service complete? - Go to Step 8 -

7. Replace the HO2S. Refer to the "Replacement of HO2S".


- Go to Step 8 -

8.

1. Use a scan tool in order to clear DTCs.

2. Operate the vehicle within the Failure Records

conditions.

Does the DTC reset?



6.4C.4.9 DTC P0137 Downstream oxygen sensor circuit short to earth

Circuit description


grounding (ECU terminal pin B_ E2), signal terminal (ECU terminal pin B_ A3) and heater control terminal (ECU terminal

pin B_ 04).






fuel injected according to the gas mixture concentration sent by the signal. P0137 will be set up on conditions that the

signal is always suppressed in the range lower than the reference voltage.


Internal resistence of back oxygen sensor < 10 Ohm

Measuring voltage of back oxygen sensor < 0.11V









DTC P0137 Downstream oxygen sensor circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2.


parameters.

2. With a scan tool, observe the HO2S voltage

parameter.

Is the HO2S voltage at the specified value?


3.

Operate the vehicle within the Failure Records

conditions.

Does the scan tool indicate this DTC failed this ignition?

- Go to Step 4

Go to

"Diagnostic

aids"

4.

1. Disconnect the HO2S.


Does the scan tool indicate that the HO2S voltage is at

the specified value?


5.

Test the HO2S signal circuit for a short to ground or a

short to sensor ground. Refer to "Circuit testing" and

"Wiring repairs" in "Wiring

systems".



6. Is the service complete? - Go to Step 8 -

7. Replace the HO2S. Refer to the "Replacement of HO2S".

Is the service complete? - Go to Step 8 -

8.

1. Use a scan tool in order to clear DTCs.

2. Operate the vehicle within the Failure Records

conditions.

Does the DTC reset?



6.4C.4.10 DTC P0132 Upstream oxygen sensor circuit short to power

Circuit description


grounding (ECU terminal pin B_F2), signal terminal (ECU pin B_C1) and heater control terminal (ECU terminal pin

B_N4).


circuit. Oxugen sensor inputs oxygen sensor voltage through the ECU pin B_C1. The oxygen sensor signal voltage will




fuel injected according to the gas mixture concentration sent by the signal. If the oxygen sensor signal voltage is too

high and kept for quite long a period, configure DTC P0132.


Ignition switch is in the state of ON.

Upstream oxygen sensor voltage is higher than 4.78V.








Aids for diagnosis

Check for the following items:

Fuel pressure- if it’s too high, the system will get rich. ECU can compensate a little for the increase. However, if the

fuel pressure is too high, configure P0132.

Check evaporative emission canister fuel saturation. If fuel is full, check canister control and hose.

Interrupted output of throttle position (TP) sensor may lead the system to getting richer because of the false

indication of engine acceleration.

Check fuel pressure regulator diaphragm for leakage by examining the regulator vacuum line for the sign of fuel.

Leaking spray nozzle requires replacement.


P0132 Upstream oxygen sensor circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2.



running the DTC".


information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

Monitor the data display of oxygen sensor (HO2S) with

the scan tool.

Is the data display of O2S more than the specified value?

4780 mV Go to Step 4

Go to

"Diagnostic

aids"

4.

Perform the commissioning, speed up the vehicle to

more than 40 km/hour and then close the throttle. Under

the engine deceleration fuel mode, observe the voltage

value of O2S when the opening of throttle is less than

3%.

Does the voltage of O2S approximate the specified

value?

110 mV

Go to

"Diagnostic

aids"

Go to Step 5

5.




Does the scan tool indicate that the O2S voltage is more

than the specified value?


6. Test the signal circuit of the HO2S for a short to voltage.

Did you find and correct the condition? - Go to Step 9 Go to Step 8



8. Replace the ECU.


9.

1. Clear the DTCs.





current?



6.4C.4.11 DTC P0138 Downstream oxygen sensor circuit short to power

Circuit description


grounding (ECU terminal pin B_ E2), signal terminal (ECU terminal pin B_ A3) and heater control terminal (ECU terminal

pin B_ 04).


circuit. Oxugen sensor inputs oxygen sensor voltage through the ECU pin B_A3. The oxygen sensor signal voltage will




fuel injected according to the gas mixture concentration sent by the signal. If the oxygen sensor signal voltage is too

high and kept for quite long a period, configure DTC P0138.


Ignition switch is in the state of ON.

Upstream oxygen sensor voltage is higher than 4.78V.








Aids for diagnosis

Check for the following items:

Fuel pressure- if it’s too high, the system will get rich. ECU can compensate a little for the increase. However, if the

fuel pressure is too high, configure P0138.

Check evaporative emission canister fuel saturation. If fuel is full, check canister control and hose.

Interrupted output of throttle position (TP) sensor may lead the system to getting richer because of the false

indication of engine acceleration.

Check fuel pressure regulator diaphragm for leakage by examining the regulator vacuum line for the sign of fuel.

Leaking spray nozzle requires replacement.


DTC P0138 Downstream oxygen sensor short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2.



running the DTC".


information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

Monitor the data display of oxygen sensor (HO2S) with

the scan tool.

Is the data display of O2S more than the specified value?

4780 mV Go to Step 4

Go to

"Diagnostic

aids"

4.

Perform the commissioning, speed up the vehicle to

more than 40 km/hour and then close the throttle. Under

the engine deceleration fuel mode, observe the voltage

value of O2S when the opening of throttle is less than

3%.

Does the voltage of O2S approximate the specified

value?

110 mV

Go to

"Diagnostic

aids"

Go to Step 5

5.




Does the scan tool indicate that the O2S voltage is more



6. Test the signal circuit of the HO2S for a short to voltage.




8. Replace the ECU.


9.

1. Clear the DTCs.





current?



6.4C.4.12 DTC P0031 Upstream oxygen sensor heater control circuit open or short to earth

Circuit description

Heated oxygen sensor (HO2S) heater shortens time needed for oxygen sensor to reach operating temperature and

keeps the temperature during the long idle running period. When ignition switch is in “ON” position, ignition voltage is

directly supplied to oxygen sensor heater. Engine control module (ECM) will first make control circuit bonding to control

heater operations when oxygen sensor is in a cold state. Prevent through control of sensor heating speed the possibility

of sensor thermal shock as a result of dew formation of the sensor. After a predetermined period, ECM gives instruction

of continuous connection of the heater. Immediately the oxygen sensor operating temperature is reached, ECM will

make the heater control circuit bonding maintain the expected temperature.

ECM will control the heater through control circuit bonding and this control circuit consists of the solid-state device

known as actuator. The actuator is fitted with a reactive circuit connected to the voltage. ECM determines on the basis of

monitoring feedback voltage whether control circuit is open, short to the bonding or to the voltage. If control circuit

detected by ECM when the control circuit is instructed to disconnect is lower than the predetermined value, configure

this DTC.


Heater control circuit open or short to earth








DTC P0031 Upstream oxygen sensor heater control circuit open or short to earth

Step Action Yes No

1 Connect the diagnosis instrument and set ignition switch to “ON”. Go to Step 2

2

Unplug oxygen sensor connector from the wiring harness. Check

whether the voltage between line ZK5 of this connector and line

B_N4 pin is about 12V with a multimeter.


3

Check with a multimeter whether the resistance between the

oxygen sensor and corresponding pins of line ZK5 and B_N4 is

8~12Ω at a temperature of 20℃.

Go to Step 4 Replace the

sensor

4 Check whether fuse F215 in main relay power supply line is blown. Replace the fuse Go to Step 5

5

Check whether circuits between pins of B_N4 in ECU and ZK5 of

main relay and corresponding pins of line ZK5 and B_N4 is open

or short to earth.

Repair or replace the

wiring harness Diagnostic aids


6.4C.4.13 DTC P0037 Downstream oxygen sensor heater control circuit open or short to

earth

Circuit description










monitoring feedback voltage whether control circuit is open, short to the bonding or to the voltage. If control circuit

detected by ECM when the control circuit is instructed to disconnect is lower than the predetermined value, configure

this DTC.


Heater control circuit open or short to earth








DTC P0037 Downstream oxygen sensor heater control circuit open or short to earth

Step Action Yes No


2



B_O4 pins is About 12V with a multimeter.


3


oxygen sensor and corresponding pins of line ZK6 and B_O4 is



sensor


5

Check whether circuits between pins of B_O4 in ECU and ZK6 of

main relay and corresponding pins of line ZK6 and B_O4 is open

or short to earth.




6.4C.4.14 DTC P0032 Upstream oxygen sensor heater control circuit short to power

Circuit description










monitoring feedback voltage whether control circuit is open, short to the bonding or to the voltage.If control circuit

detected by ECM when the control circuit is instructed to disconnect is higher than the predetermined value, configure

this DTC.


Pre-catalyst lambda probe heater control circuit short to power;








DTC P0032 Upstream oxygen sensor heater control circuit short to power

Step Action Yes No


2



B_N4 pins is About 12V with a multimeter.


3


oxygen sensor and corresponding pins of line ZK6 and B_N4 is



sensor


5

Check whether circuits between pins of B_N4 in ECU and ZK6 of

main relay and corresponding pins of line ZK6 and B_N4 is short

to power.




6.4C.4.15 DTC P0038 Downstream oxygen sensor heater control circuit short to power

Circuit description









known as actuator. The actuator is fitted with a feedback circuit connected to the voltage. ECM determines on the basis

of monitoring feedback voltage whether control circuit is open, short to the bonding or to the voltage. If control circuit

detected by ECM when the control circuit is instructed to disconnect is higher than the predetermined value, configure

this DTC.


Heater control circuit short to power;








DTC P0038 Downstream oxygen sensor heater control circuit short to power

Step Action Yes No


2



B_O4 pins is About 12V with a multimeter.


3


oxygen sensor and corresponding pins of line ZK6 and B_O4 is



sensor


5

Check whether circuits between pins of B_O4 in ECU and ZK6 of

main relay and corresponding pins of line ZK6 and B_O4 is short

to power.




6.4C.4.16 DTC P0106 Improper intake manifold pressure sensor signal

Circuit description

This sensor consists of two sensors, namely, intake manifold absolute pressure sensor and intake temperature sensor.

There are three pins connect to this sensor (short as MAP) respectively 5V reference voltage (A_F4), grounding terminal

(A_B4) and signal output terminal（A_G2）.In the certain measuring range, pressure applied on the sensor and

measuring signal (voltage signal) presents a linear relation, i.e., the characteristic curve of the pressure sensor. ECU will

in accordance with the characteristic curve convert the voltage signal received to intake pressure. In malfunction

diagnosis test, ECU will process the intake pressure sensor output voltage into the average output voltage within the

period of every 180°rotation of the crankshaft and take it as diagnosis module input to assess the malfunction.


The difference between the manifold pressure at engine stop and at engine idle is less than 25hPa

450hpa < manifold pressure at engine stop or engine off <1100hpa

Throttle percentage: 1%~7%



Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 1 continuous driving cycle.





Aids for diagnosis


Poor connection between ECU and intake pressure sensor-check ECU wiring harness connector;

Loosening terminals;

Poor match connection;

Broken keeper;

Deformed or damaged terminal;

Poor connection of terminal with the wire;

Damaged wiring harness-check if wiring harness is damaged. If the wiring harness looks normal, watch the intake

pressure displayed on the malfunction diagnosis instrument while moving connectors and wiring harness related with

the sensor. If the display shows difference, it indicates defects in this section. If the diagnostic trouble code cannot be

represented and is determined as intermittent, it will be of help to check malfunction records in determining the latest

time when the code was set.


DTC P0106 Improper intake manifold pressure sensor signal




Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. If the engine idle is unstable, repair the idle problem

before continuing with this table.

2. Install a scan tool. Start the engine and allow it to

idle.


information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3

Monitor the data display of intake pressure sensor (MAP)

using a scan tool.

Is the sensor data display greater than the specified

value?

0.5V Go to Step 4 Go to Step 5

4

Conduct a 4.8-5.2 V load test between the 5 V reference

voltage circuit of intake manifold absolute pressure

sensor and the ground.

Is it between the reference values?

4.8-5.2V Go to Step 9 Go to Step 5

5

Turn ON the ignition. Test whether the voltage between

the low-voltage reference circuit of intake manifold

absolute pressure sensor and the battery negative pole is

greater than 0.2 V.

Turn Off the ignition. Test whether the resistance

between the low-voltage reference circuit of intake

manifold absolute pressure sensor and the battery

negative pole is greater than 5Ω.


6

Turn ON the ignition. Install a 3 A fused jumper wire

between the signal circuit and the low-voltage reference

circuit of intake manifold absolute pressure sensor.

Check whether the parameter of intake manifold absolute

pressure sensor is lower than the reference value.

120 kPa Go to Step 7 Go to Step 9

7

Test the 5 V voltage circuit and signal circuit of MAP for a

short to ground. Test for the short circuit or open circuit in

MAP circuit, for the high resistance in wiring harness or

for the poor contact of pins at ECU end or sensor end.



8 Replace the MAP.


9 Replace the ECM.


10

1. Clear the DTC.

2. Restart the engine. Use the scan tool to monitor the



current?



6.4C.4.17 DTC P0107 Intake manifold pressure sensor circuit short to earth

Circuit description



(A_B4) and signal output terminal (A_G2）. In the certain measuring range, pressure applied on the sensor and

measuring signal presents a linear relation, i.e., the characteristic curve of the pressure sensor. ECU will in accordance

with the characteristic curve convert the voltage signal received to intake pressure. When the sensor is in good working

condition, the output voltage should be 0.5V－4.65V (with corresponding intake pressure between 10kPa and 115kPa).

In malfunction diagnosis test, ECU will process the intake pressure sensor output voltage into the average output

voltage within the period of every 180°rotation of the crankshaft and take it as diagnosis module input to assess the

malfunction. If pressure voltage of intake manifold absolute pressure sensor detected by ECM is too low, configure DTC

P0107。


Engine is in operation;

Voltage of intake pressure sensor is lower than 0.46V.








Aids for diagnosis





Broken keeper;




pressure displayed on the scanning instrument while moving connectors and wiring harness related with the sensor. If

the display shows difference, it indicates defects in this section.

If the diagnostic trouble code cannot be represented and is determined as intermittent, it will be of help to check fault

records in determining the latest time when the code was set.


DTC P0107 Intake manifold pressure sensor circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2




idle.


information. Does the scan tool indicate that the

DTC P0107 is current?

- Go to Step 3

Go to

"Diagnostic

aids"

3

Use the scan tool to monitor the data display of intake

pressure sensor (MAP).

Is the sensor data display lower than the specified value?

0.5V Go to Step 4

Go to

"Diagnostic

aids"

4

1. Turn the ignition switch off.

2. Disconnect the MAP sensor connector.


4. Measure voltage between MAP wiring harness plug

A_F4 pin and the ground.

Is voltage value is near the specified value?

5V Go to Step 5 Go to Step 6

5. Test the signal circuit of MAP for a short to ground.


6

Test for the short circuit or open circuit in MAP circuit, for

the high resistance in wiring harness or for the poor

contact of pins at ECU end or sensor end.



7

Inspect MAP. Remove MAP, connect sensor terminal to

vacuum gauge, corresponding MAP pin of wiring harness

terminal A_F4 pin to 5V DC, corresponding MAP pin of

wiring harness terminal A_B4 pin to the ground, and

corresponding MAP pin of wiring harness terminal A_G2

pin to a multimeter. Does multimeter voltage decrease

from 4.65V to 0.4V correspondingly when vacuum meter

pressure drops from 115KPa to 10KPa?


8 Replace the MAP.

Is the replacement complete? - Go to Step 10

9 Replace the ECU.


10

1. Clear the DTC.




current?



6.4C.4.18 DTC P0108 Intake manifold pressure sensor circuit short to power

Circuit description



(A_B4) and signal output terminal（A_G2）. In the certain measuring range, pressure applied on the sensor and

measuring signal presents a linear relation, namely a characteristic curve of the pressure sensor. ECU will in

accordance with the characteristic curve convert the voltage signal received to intake pressure. When the sensor is in

good working condition, the output voltage should be 0.4V-4.65V (with corresponding intake pressure between 10kPa

and 115kPa). In malfunction diagnosis test, ECU will process the intake pressure sensor output voltage into the average

output voltage within the period of every 180°rotation of the crankshaft and take it as diagnosis module input to assess

the malfunction. If pressure voltage of intake manifold absolute pressure sensor detected by ECM is too high, configure

DTC P0108.


The average output voltage of intake air pressure sensor ＞4.93V








Aids for diagnosis





Broken keeper;




pressure displayed on the scanning instrument while moving connectors and wiring harness related with the sensor.

If the display shows difference, it indicates defects in this section.

If the diagnostic trouble code cannot be represented and is determined as intermittent, it will be of help to check

malfunction records in determining the latest time when the code was set.


DTC P0108 Intake manifold pressure sensor circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2




idle.


information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3

Use the scan tool to monitor the data display of intake

pressure sensor (MAP). Is the sensor data display higher


4.950V Go to Step 4

Go to

"Diagnostic

aids"

4

1. Turn the ignition switch off.

2. Disconnect the MAP sensor connector.


4. Measure voltage between MAP wiring harness plug

A_F4 pin and the ground.

Is voltage value is near the specified value?


5. Test the signal circuit of MAP for a short to ground.


6

Test for the short circuit or open circuit in MAP circuit, for

the high resistance in wiring harness or for the poor




7

Inspect MAP. Remove MAP, connect sensor terminal to

vacuum gauge, corresponding MAP pin of wiring harness

terminal A_F4 pin to 5V DC, corresponding MAP pin of

wiring harness terminal A_B4 pin to the ground, and

corresponding MAP pin of wiring harness terminal A_G2

pin to a multimeter. Does multimeter voltage decrease

from 4.65V to 0.4V correspondingly when vacuum meter

pressure drops from 115KPa to 10KPa?


8 Replace the MAP.

Is the replacement complete? - Go to Step 10

9 Replace the ECU.


10

1. Clear the DTC.




current?



6.4C.4.19 DTC P0112 Intake temperature sensor circuit short to earth

Circuit description


There are two pins connect to this sensor, respectively the signal terminal (A_E4) and grounding terminal (A_C2).

Measuring component of the intake temperature sensor is a resistor with negative temperature coefficient. When intake

air temperature is low, sensor resistance and voltage of temperature signal input into ECU will be high. When intake air

temperature is high, sensor resistance and voltage of temperature signal input into ECU will be low. When temperature

sensor functions well, intake temperature taken by the system equals the intake temperature indicated by temperature

signal voltage. If temperature signal terminal is short to earth, corresponding indicated intake temperature will be too

high and DTC P0112 will be configured.


Voltage of intake air temperature sensor ＜ 0.08V

Engine starting time＞120S



Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 2 continuous driving cycles.





Aids for diagnosis


Poor connection between ECU and intake temperature sensor-check if ECU wiring harness connector exists;

Loosen end

Poor matching and connection

Locking plate fracture

Deformation or damage of end

Poor contact of end and wire

If the wire harness is damaged - check whether the wire harness is damaged. If it is seemingly normal, when

moving the connectors and wiring harness related to the IAT sensor, observe the IATon the scanning tools. If the

IAT has change, there is fault.


DTC P0112 Intake temperature sensor circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2.

1. Turn the ignition to ON without starting the engine.

2. With a scan tool, observe the IAT parameter.

Does the scan tool indicate that the IAT parameter is

more than specified value?

120°C Go to Step 4 Go to Step 3

3.

Operate the vehicle within conditions for running the

DTC.


current?

- Go to Step 4

Go to

"Diagnostic

aids"

4.


2. Disconnect the IAT sensor.


With a scan tool, observe the IAT parameter.


lower than specified value?

-40°C Go to Step 6 Go to Step 5

5.

Test the signal circuit of the IAT sensor for a short to

ground.



6.

Check for the high resistance in the circuit between IAT

and ECU or for the poor contact of pins at ECU end or

sensor end.



7. Replace the IAT sensor.


8. Replace the ECU.


9.

1. Use the scan tool to clear the DTC.

2. Operate the vehicle within the conditions for

running the DTC.

Is the DTC reset?



6.4C.4.20 DTC P0113 Intake temperature sensor circuit short to power

Circuit description


There are two pins connect to this sensor, respectively the signal terminal (A_E4) and grounding terminal (A_C2).

Measuring component of the intake temperature sensor is a resistor with negative temperature coefficient. When intake

air temperature is low, sensor resistance and voltage of temperature signal input into ECU will be high. When intake air

temperature is high, sensor resistance and voltage of temperature signal input into ECU will be low. When temperature

sensor functions well, intake temperature taken by the system equals the intake temperature indicated by temperature

signal voltage. If temperature signal terminal is short to earth, corresponding indicated intake temperature will be too

high and DTC P0113 will be configured.


Voltage of air intake temperature sensor > 4.95 V

Minimum time of engine starting > 120 s








Aids for diagnosis

Checking the following situation:

Poor contact of ECU and intake air temperature sensor – check if wire harness connector of ECU exists:

Loose end

Poor matching and connection

locking plate fracture

Deformation or damage of end

Poor contact of end and wire

If the wire harness is damaged - check whether the wire harness is damaged. If it is seemingly normal, when

moving the connectors and wiring harness related to the IAT sensor, observe the IATon the scanning tools. If the

IAT has change, there is fault.


DTC P0113 Intake temperature sensor circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2.


2. With a scan tool, observe the IAT parameter.


lower than specified value?


3.

Operate the vehicle within conditions for running the

DTC.


current?

- Go to Step 4

Go to

"Diagnostic

aids"

4.


2. Disconnect the IAT sensor.

3. Use a 3 A jumper wire to connect the ground wire of

sensor and the signal wire.

Turn ON the ignition. With a scan tool, observe the IAT

parameter.


more than the specified value?


5.

1. Use an end of jumper wire to connect the pin at the

signal end of IAT sensor. The other end ensures a

good ground.

2. Use the scan tool to observe the IAT parameter.




6.

Test the signal wire of the IAT for the short circuit to

power supply or open circuit.



7.

Check for the short circuit, open circuit or high resistance

in the circuit between IAT and ECU or for the poor




8. Replace the IAT sensor.

Is the replacement complete? - Go to Step10 -

9. Replace the ECU.


10.


2. Operate the vehicle within the conditions for running

the DTC.

Is the DTC reset?



6.4C.4.21 DTC P0117 Engine coolant temperature sensor circuit short to earth

Circuit description

There are two pins connect to the engine coolant temperature sensor, respectively the sensor signal terminal (ECU pin

A_D3) and grounding terminal (ECU pin A_B2).

Measuring component of the engine coolant temperature sensor by this system is a resistor with negative temperature

coefficient. Its resistance will decrease as the temperature increases, resulting in the corresponding decrease of input

ECU signal value in the form of voltage. The voltage varies in 0~5V range. Through checking the sensor characteristic

curve, ECU converts it into engine coolant temperature. The diagnostic module of engine coolant temperature sensor

determines on the basis of this temperature the malfunction.


Engine coolant temperature sensor voltage is less than 0.15 V



Malfunction indicating lamp will be lit when malfunction is detected in 1 continuous driving cycle.





Aids for diagnosis


Poor connection between ECU and engine coolant temperature sensor-check if ECU wiring harness connector exists;



Broken keeper

Deformed or damaged terminal

Poor connection of terminal with the wire

Damage of wire harness:

Check whether the wire harness is damaged. If it is seemingly normal, when moving the connectors and wiring harness

related to the ECT, observe the ECT on the malfunction diagnosis instrument. If the ECT has change, there is fault.

If the DTC cannot be represented, it will be of help to check malfunction records in determining driving distance since

the last time when DTC was set. The frequency of setting DTC can be determined, which is helpful to the diagnosis of

this situation.


DTC P0117 Engine coolant temperature sensor circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2.

● Turn the ignition to ON without starting the engine.

● With a scan tool, observe the ECT parameter.

Does the scan tool indicate that the ECT parameter is



3.

Operate the vehicle within the conditions for running the

DTC.


current?

- Go to Step 4

Go to

"Diagnostic

aids"

4.

1. Turn the ignition OFF.

2. Disconnect the ECT sensor.


4. Observe the ECT parameter with a scan tool.


less than the specified value?

- 40°C Go to Step 6 Go to Step 5

5.

Test the ECT sensor signal circuit for a short to ground or

a short to the coolant temperature sensor ground circuit.



6. Replace the ECT sensor.


7. Replace the ECU.


8.



the DTC.

Is the DTC reset?



6.4C.4.22 DTC P0118 Engine coolant temperature sensor circuit short to power or open

Circuit description

There are two pins connected to engine coolant temperature (ECT) sensor, respectively the sensor signal terminal

(ECU pin A_D3) and sensor ground terminal (ECU pin A_B2).

Measuring component of the engine coolant temperature sensor by this system is a resistor with negative temperature

coefficient. Its resistance will decrease as the temperature increases, resulting in the corresponding decrease of input

ECU signal value in the form of voltage. The voltage varies in 0~5V range. Through checking the sensor characteristic

curve, ECU converts it into engine coolant temperature. The diagnostic module of engine coolant temperature sensor

determines on the basis of this temperature the malfunction.


Original voltage value of water temperature sensor is greater than 4.93 V

Temperature of intake air temperature sensor > - 30 ℃ or ≤ 30 ℃

Engine starting time > 60 s








Aids for diagnosis


Poor connection between ECU and engine coolant temperature sensor-check if ECU wiring harness connector exists;



Broken keeper

Deformed or damaged terminal


Damaged wiring harness:

Check if wiring harness is damaged. If the wiring harness looks normal, watch the ECT displayed on the malfunction

diagnosis instrument while moving connectors and wiring harness related with ECT sensor. If the ECT shows difference,

it indicates defects in this section.

If the DTC cannot be represented, it will be of help to check malfunction records in determining driving distance since

the last time when the code was set. The frequency of setting DTC can be determined, which is helpful to the diagnosis

of this situation.


DTC P0118 Engine coolant temperature sensor circuit short to power or circuit break




Go to "Check of

powertrain

on-board

diagnostic

system"

2.

● Turn the ignition to ON without starting the engine.

● With a scan tool, observe the ECT parameter.


lower than the specified value?

- 40°C Go to Step 4 Go to Step 3

3.

Operate the vehicle within the conditions for running the

DTC.

Does the scan tool indicate that DTC P0118 failed this

ignition?

- Go to Step 4

Go to

"Diagnostic

aids"

4.

Test for the short circuit to power supply of ECT sensor

signal circuit.



5.

1. Turn the ignition off.

2. Disconnect the ECT sensor.

3. Connect the jumper wire with a 3 A fuse between the

ECT sensor signal circuit and the ground circuit.

4. Use the scan tool to observe the ECT parameter.




6.

1. Use an end of jumper wire with a 3 A fuse to connect

the ECT sensor signal terminal. The other end

ensures a good ground.

2. Use the scan tool to observe the ECT parameter.




7. Inspect for faulty connections at the ECT sensor.


8. Test the ground circuit of the ECT sensor for an open.


9. Test the signal circuit of the ECT sensor for an open.


10.

Check for the connection of ECT sensor signal and

ground circuit on the ECU.



11. Replace the ECT sensor.


12. Replace the ECU module.


13.

● Use the scan tool to clear the DTC.

● Operate the vehicle within the conditions for running

the DTC.

Is the DTC reset?



6.4C.4.23 DTC P0119 Engine coolant temperature sensor signal gradient failure

Circuit description

The engine coolant temperature (ECT) sensor is a variable resistor that measures the temperature of the engine coolant.

The engine control module (ECM) supplies 5 volts to the ECT signal circuit and supplies a ground to the low reference

circuit. The ECM tests the coolant temperature sensor. If the ECM detects the too high noise or rapid fluctuation of the

ECT signal, this DTC sets.

The following table illustrates the difference between temperature, resistance, and voltage:

ECT ECT resistance ECT signal voltage

Cold High High

Warm Low Low


Temperature change of engine water temperature sensor within 1.5S interval > 5.25 V








Aids for diagnosis

Check engine coolant temperature sensor at different temperature levels for errors. Sensor error will lead to DTC

failure or driveability failure. See “Temperature and resistance-engine coolant temperature sensor”.

When engine starts the cooling, temperature of engine coolant temperature sensor should rise steadily and keep

stable when thermostat is started.

If resistance of engine coolant temperature sensor signal circuit or engine coolant temperature sensor low level

reference voltage circuit is too high, DTC may be configured.


DTC P0119 Engine coolant temperature sensor signal gradient failure


1 Did you perform the "Check of diagnostic system -

vehicle"? Go to Step 2

Go to "Check of

diagnostic

system -

vehicle" in

"Vehicle DTC

information"

2

Observe the engine coolant temperature (ECT) sensor

parameter change with a scan tool while moving the ECT

sensor connector and the engine control module (ECM)

connector as well as the relevant wiring harnesses.

Is the parameter change more than the specified value?

3°C（5°F） Go to Step 3 Go to Step 4

3 Repair the suspected harness and connector. Is the

repair complete? Go to Step 16

4

1. Check the engine coolant height.

2. Check and confirm the operating condition of coolant

system.

Is there any suspected malfunction of engine cooling

system?

Go to "Symptom

- engine cooling

system"

Go to Step 5

5

1. Observe the "Freeze Frame/Failure Records" for this

DTC.

2. Turn the ignition OFF for 30 seconds.


4. Operate the vehicle within the "Conditions for running

the DTC". You may also operate the vehicle within

the conditions that you observed from the "Freeze

Frame/Failure Records".

Did the DTC fail this ignition?

Go to Step 6

Go to

"Diagnostic

aids"

6

1. Turn the ignition switch to the OFF position.

Disconnect the ECT sensor. Refer to the

"Replacement of ECT sensor".


3. With a scan tool, observe the ECT sensor parameter.

Is the temperature less than the specified value?


7


Disconnect the ECM.

2. Check the signal circuit of ECT sensor for a short to

ground.



8


2. Remove the ECM fuse from the underhood fuse

block.

Notice: Do NOT use a test lamp to test the continuity of

the circuit. Damage to the control module may occur due

to excessive current draw.

Important: The control module or the sensor may be

damaged if the circuit is shorted to battery positive

voltage.

3. Measure the resistance between the low reference

circuit of the ECT sensor and the ECM housing with

a DMM.

Is the resistance less than the specified value?

5Ω Go to Step 9 Go to Step 10



9

1. Turn the ignition switch to the OFF position. Install

the ECM fuse to the underhood fuse block.

2. Turn the ignition switch to the On position. Connect a

3-amp fused jumper wire between the signal circuit

and the low reference circuit of the ECT sensor.

3. With a scan tool, observe the ECT sensor parameter.

Is the temperature above the specified value?


10

Check the ECT sensor low reference circuit for an open,

for a high resistance, or for a short to voltage. Did you

find and correct the condition?


11

Check the signal circuit of the ECT sensor for a short to

voltage, an open, or for high resistance. Did you find and

correct the condition?


12

Check for shorted terminals and for poor connections at

the ECT sensor.



13

Check for shorted terminals and for poor connections at

the ECM.



14

Replace the ECT sensor. Refer to the "Replacement of

ECT sensor".

Is the replacement complete?

Go to Step 16

15 Replace the ECM.

Is the replacement complete? Go to Step 16

16

1. Use a scan tool to clear all DTCs.

2. Switch off the ignition for 30 seconds.


4. Operate the vehicle within the "Conditions for running

the DTC".



17 Observe the "Capture Info" with a scan tool.

Is there any DTC that has not been diagnosed?

Go to "DTC list -

vehicle" of

"Vehicle DTC

information"

System OK


6.4C.4.24 DTC P0123 Overtension of throttle position sensor 1

Circuit description

Throttle actuator control system utilizes 2 throttle position sensors to monitor throttle position. Throttle position sensor 1

and 2 are in throttle body assembly. The sensors have the following circuits:

A 5V reference voltage circuit;

A low reference voltage circuit;

Two throttle position sensor signal circuits;

2 processors are used meanwhile to monitor throttle actuator control system data.The 2 processors are located in

ECM.Each signal circuit supply the 2 processors with signal voltage proportionate to throttle blade displacement. The 2

processors monitor data of each other to ensure correct calculation of throttle position. Signals of sensor 1 and 2 are

complementary.


Throttle position voltage is higher than 4.87V.









DTC P0123 Overtension of throttle position sensor 1


1 Did you perform the "Check of diagnostic system - engine

control system"? - Go to Step 2

Go to "Check

diagnostic

system - engine

control system"

2


2. Allow the engine to idle

3. Observe the TP sensor percentage parameter with

a scan tool.

Is the percentage less than the specified value?

12% Go to Step 4 Go to Step 3

3

1. Observe the "Freeze Frame/Failure Records" for

this DTC.



running the DTC". You may also operate the vehicle

within the conditions that you observed from the

"Freeze Frame/Failure Records".

Does the DTC fail this ignition cycle?

- Go to Step 4

Go to

"Intermittent

conditions"

4

1. Turn the ignition switch OFF.

2. Disconnect the TP sensor.

3. Turn ON the ignition with the engine OFF.

4. Observe the TP sensor percentage parameter with

a scan tool.

Is the percentage less than the specified value?


5

Measure the voltage from the 5 V reference circuit of the

TP sensor to a good ground.

Is the voltage value more than the specified value?


6

Measure the resistance between the low reference circuit

of the TP sensor and the engine control module (ECM)

housing with a DMM. Is the resistance value below the

specified value?

5 Ω Go to Step 10 Go to Step 8

7 Test the signal circuit of TP sensor for a short to voltage.


8

Important: The ECM and the TP sensor may be

damaged if the circuit is shorted to battery positive

voltage.

Test the low reference circuit of TP sensor for the

following conditions:

A short to voltage

An open circuit

Too high resistance



9

Important: The 5-volt reference circuits are internally

and externally connected at the controller. Other sensors

that share the 5-volt reference circuit may also have

DTCs set. Disconnecting a sensor on the shared 5-volt

reference circuit may isolate a shorted sensor. Review

the electrical schematic and diagnose the shared

circuits and relevant sensors. Test the 5-volt reference

circuit of the TP sensor for a short to voltage.





10

Check the TP sensor for intermittent and poor

connections.



11 Test the ECM for intermittent and poor connections.


12 Replace the TP sensor.


13 Replace the ECM.


14

1. Use the scan tool in order to clear the DTC.




running the DTC". You may also operate the vehicle

within the conditions that you observed from the

"Freeze Frame/Failure Records".

Does the DTC fail this ignition cycle?



Is there any DTC that has not been diagnosed? - Go to "DTC list" System OK


6.4C.4.25 DTC P0122 Low voltage of throttle position sensor 1

Circuit description

Throttle actuator control (TAC) system utilizes 2 throttle position sensors to monitor throttle position. Throttle position

sensor 1 and 2 are in throttle body assembly. The sensors have the following circuits:




2 processors are used meanwhile to monitor throttle actuator control system data. The 2 processors are located in ECM.

Each signal circuit supply the 2 processors with signal voltage proportionate to throttle blade displacement. The 2


complementary.


Voltage of the throttle position sensor signal is lower than 0.16V.









DTC P0122 Low voltage of throttle position sensor 1


1 Is “Diagnosis system check-engine control system”

already executed? - Go to Step 2

Go to "Check

diagnostic

system - engine

control system"

2

1. Connect ignition switch but do not start the engine.

2. Step on accelerator pedal to wide open throttle

(WOT) position and monitor throttle position (TP)

sensor opening on the malfunction diagnosis

instrument at the same time.

Does TP sensor opening increase from below the first

specified value to above the second specified value?

12%-88% Go to Step 3 Go to Step 4

3

1. Check “Freeze Frame” /”Failure Records” of the

DTC.

2. Shut the ignition switch for 30s.


4. Under “conditions for running DTC”, handle the

vehicle.You can also handle the vehicle under the

condition checked in “Freeze Frame” / “Failure

Records”.

Does DTC fail to pass this ignition loop test?

- Go to Step 4

Go to

"Intermittent

conditions"

4

1. Shut the ignition switch.

2. Disconnect throttle position sensor.


4. Measure the voltage between throttle position

sensor 5V reference voltage circuit and the reliable

ground point with a digital multimeter.

Does the voltage exceed the specified value?


5

1. Connect a jumper wire with a 3A fuse between

throttle position sensor 5V reference voltage circuit

and the signal circuit.

2. Observe through the malfunction diagnosis

instrument throttle position sensor percentage

parameter.

Does the percent exceed the specified value?


6

Measure the resistance between throttle position sensor

low reference voltage circuit and ECM housing with a

digital multimeter.

Does the resistance exceed the specified value?


7

Important note: Each 5V reference voltage circuit is

connected inside and outside the controller. Other

sensors sharing the 5V reference voltage circuit may also

lead to configuration of DTC. Disconnecting a certain

sensor sharing the 5V reference voltage circuit can

insulate the short-circuited sensor.

Refer to electrical schematic diagrams to diagnose the

shared circuit and related sensors.

Test the throttle position sensor 5V reference voltage

circuit for the following conditions:

Open circuit;

Short to earth;

Over-high resistance;




Is failure detected and resolved?

8

Test the throttle position sensor signal circuit for the


Open circuit;

Short to earth;




9

Important note: if low reference voltage circuit is short to

battery positive voltage, ECM and/or TP sensor may be

damaged. Test the throttle position sensor low reference

voltage circuit for the following conditions:

Open circuit;


Short circuit to voltage;



10

Check the TP sensor for intermittent failure and poor

connection defect.



11

Test ECM for intermittent failure and poor connection

defect.



12 Replace throttle position sensor. Is replacement

finished? - Go to Step 14 -

13 Replace the ECM. Is replacement finished? - Go to Step 14 -

14

1. DTC can be cleared with a malfunction diagnosis

instrument.




vehicle. You can also handle the vehicle under the

condition checked in “Freeze Frame” /”Failure

Records”.



15 Check if there is any DTC that has not been diagnosed

with a malfunction diagnosis instrument? - Go to "DTC list" System OK


6.4C.4.26 DTC P0223 Overtension of throttle position sensor 2

Circuit description

Throttle actuator control system utilizes 2 throttle position sensors to monitor throttle position.Throttle position sensor 1

and 2 are in throttle body assembly.The sensors have the following circuits:





ECM.Each signal circuit supply the 2 processors with signal voltage proportionate to throttle blade displacement.The 2

processors monitor data of each other to ensure correct calculation of throttle position.Signals of sensor 1 and 2 are

complementary.


The throttle position is greater than 4.872V.









DTC P0223 Overtension of throttle position sensor 2




Go to "Check

diagnostic

system - engine

control system"

2


2. Let the engine run at idle state.



parameter.

Is the percent below the specified value?


3


DTC.


3. Under“conditions for running DTC”, handle the



Records”.


- Go to Step 4

Go to

"Intermittent

conditions"

4






parameter.

Is the percent below the specified value?


5

Measure the voltage between throttle position sensor 5V

reference voltage circuit and the reliable ground point.

Does the measured voltage exceed the specified value?


6



digital multimeter.

Is the resistance below the specified value?


7

Test the throttle position sensor signal circuit for short

circuit to voltage.



8

Important note: if the circuit is short to battery positive

voltage, ECM and/or TP sensor may be damaged.

Test the throttle position sensor low reference voltage

circuit for the following conditions:


Open circuit;




9




lead to configuration of DTC.Disconnecting a certain


insulate the short-circuited sensor.Refer to electrical

schematic diagrams to diagnose the shared circuit and

related sensors. Test the throttle position sensor 5V




reference voltage circuit for short circuit to voltage.


10


connection defect.



11


defect.



12 Replace throttle position sensor. Is replacement finished? - Go to Step 14 -


14


instrument.






Records”.



15

Check “Capture Info” with the a malfunction diagnosis

instrument.


- Go to "DTC list" System OK


6.4C.4.27 DTC P0222 Low voltage of throttle position sensor 2

Circuit description

Throttle actuator control (TAC) system utilizes 2 throttle position sensors to monitor throttle position.Throttle position

sensor 1 and 2 are in throttle body assembly.The sensors have the following circuits:




2 processors are used meanwhile to monitor throttle actuator control system data. The 2 processors are located in ECM.

Each signal circuit supply the 2 processors with signal voltage proportionate to throttle blade displacement. The 2


complementary.


Throttle position is lower than 0.11V.









DTC P0222 Low voltage of throttle position sensor 2




Go to "Check

diagnostic

system - engine

control system"

2


2. Step on accelerator pedal to wide open throttle

(WOT) position and monitor throttle position (TP)

sensor opening on the malfunction diagnosis

instrument at the same time.

Does TP sensor opening increase from below the first

specified value to above the second specified value?

12%-88% Go to Step 3 Go to Step 4

3


DTC.






Records”.


- Go to Step 4

Go to

"Intermittent

conditions"

4




4. Measure the voltage between throttle position

sensor 5V reference voltage circuit and the reliable

ground point with a digital multimeter.

Does the voltage exceed the specified value?


5

1. Connect a jumper wire with a 3A fuse between

throttle position sensor 5V reference voltage circuit

and the signal circuit.



parameter.

Does the percent exceed the specified value?


6



digital multimeter.

Does the resistance exceed the specified value?


7




lead to configuration of DTC.Disconnecting a certain


insulate the short-circuited sensor.

Refer to electrical schematic diagrams to diagnose the

shared circuit and related sensors. Test the throttle

position sensor 5V reference voltage circuit for the


Open circuit;

Short to earth;






8

Test the throttle position sensor signal circuit for the


Open circuit;

Short to earth;




9

Important note: if low reference voltage circuit is short to

battery positive voltage, ECM and/or TP sensor may be

damaged. Test the throttle position sensor low reference

voltage circuit for the following conditions:

Open circuit;





10


connection defect.



11


defect.



12 Replace throttle position sensor.Is replacement finished? - Go to Step 14 -


14


instrument.






Records”.



15 Check if there is any DTC that has not been diagnosed

with a malfunction diagnosis instrument? - Go to "DTC list" System OK


6.4C.4.28 DTC P2135 Inappropriate voltage relativity of throttle position sensor 1/2

Circuit description

Throttle actuator control (TAC) system utilizes 2 throttle position sensors to monitor throttle position. Throttle position

sensor 1 and 2 are in throttle body assembly. The sensors have the following circuits:





ECM.Each signal circuit supply the 2 processors with signal voltage proportionate to throttle blade displacement.The 2

processors monitor data of each other to ensure correct calculation of throttle position.Signals of sensor 1 and 2 are

complementary.


Deviation of throttle position sensor 1 and 2 exceeds the limit of 7.








DTC P2135 Inappropriate voltage relativity of throttle position sensor 1/2




Go to "Check

diagnostic system -

engine control

system"

2

Put ignition switch to “OFF” and disconnect the ECM and

throttle valve body assembly wiring harness plug

connector.

Go to Step 3

3

Test whether resistance between pins of reference

voltage circuit between ECM and throttle valve body

assembly is below 5Ω.


4

Test whether resistance between pins of signal voltage

circuit between ECM and throttle valve body assembly is

below 5Ω.


5 Test whether resistance between signal circuit terminals

of throttle position sensor 1 and 2 is infinite. - Go to Step 7 Go to Step 6

6

Check corresponding circuit for failures of open circuit,

over-high resistance and short circuit and repair. Clear

trouble code with malfunction diagnosis instrument and

re-read the trouble code to ensure the failure is cleared.

- - -

7 Replace throttle valve body assembly. - - -


6.4C.4.29 DTC P2123 Overtension of accelerator position sensor 1

Circuit description

Accelerator pedal assembly consists of 2 accelerator position sensors. Accelerator position sensors are installed on

accelerator pedal assembly and cannot be repaired and cannot be repaired. Voltage signal supplied by accelerator

pedal position sensors vary with pedal position. ECM supplies to each accelerator pedal position sensor a 5V reference

voltage circuit, a low level reference voltage circuit and a signal circuit.


Voltage of accelerator pedal position sensor is greater than 4.819 V.








DTC P2123 Overtension of accelerator position sensor 1




Go to "Check

diagnostic system -

engine control

system"

2 Set ignition switch to OFF and disconnect accelerator

pedal wiring harness plug connector. Go to Step 3

3

Test whether resistance between low level reference

voltage circuit terminal (green line) and bonding is below

5Ω.

- Go to Step 4 Go to Step6

4

Ignition switch is in the state of ON and test whether

voltage value between 5V reference voltage circuit

terminal (green line) and bonding is in specified range.


5

Constantly set accelerator pedal from the initial position

to wide open and test whether signal terminal (white/red)

and bonding is in specified range.


6

Check and test whether corresponding circuit is short to

bonding or open/ whether resistance is too high or short

circuit to power.


7

Check corresponding circuit and repair. Clear trouble

code with malfunction diagnosis instrument and re-read

the trouble code to ensure the failure is cleared.

- - -

8 Replace the ECM. - - -

9 Replace accelerator pedal assembly. - - -


6.4C.4.30 DTC P2122 Low voltage of accelerator position sensor 1

Circuit description


accelerator pedal assembly and cannot be repaired. Voltage signal supplied by accelerator pedal position sensors vary

with pedal position. ECM supplies to each accelerator pedal position sensor a 5V reference voltage circuit, a low level

reference voltage circuit and a signal circuit.


Voltage of throttle sensor is less than 0.171V








DTC P2122 Low voltage of accelerator position sensor 1




Go to "Check

diagnostic system -

engine control

system"



3


voltage circuit terminal (green line) and bonding is below

5Ω.


4



terminal (green line) and bonding is in specified range.


5


to wide open and test whether signal terminal (white/red)

and bonding is in specified range.


6



circuit to power.


7




- - -

8 ECM。Replace the ECM. - - -



6.4C.4.31 DTC P2128 Overtension of accelerator position sensor 2

Circuit description






Voltage of accelerator pedal position sensor is greater than 4.302V








DTC P2128 Overtension of accelerator position sensor 2




Go to "Check

diagnostic system -

engine control

system"



3


voltage circuit terminal (red line) and bonding is below

5Ω.


4



terminal (red line) and bonding is in specified range.


5


to wide open and test whether signal terminal

(white/blue) and bonding is in specified range.


6



circuit to power.


7




- - -




6.4C.4.32 DTC P2127 Low voltage of accelerator position sensor 2

Circuit description






Voltage of accelerator pedal position sensor is less than 0.078V.








DTC P2127 Low voltage of accelerator position sensor 2




Go to "Check

diagnostic system -

engine control

system"



3


voltage circuit terminal (red line) and bonding is below

5Ω.


4



terminal (red line) and bonding is in specified range.


5


to wide open and test whether signal terminal

(white/blue) and bonding is in specified range.


6



circuit to power.


7




- - -




6.4C.4.33 DTC P2138 Inappropriate voltage relativity of accelerator position sensor 1/2

Circuit description






Voltage ratio deviation of accelerator position sensor 1 and 2 exceeds the limit.








DTC P2138 Inappropriate voltage relativity of accelerator position sensor 1/2




Go to "Check

diagnostic

system - engine

control system"

2

Put ignition switch to “OFF” and disconnect the ECM and

accelerator pedal assembly wiring harness plug

connector.

Go to Step 3

3

Test whether resistance between pins of reference

voltage circuit between ECM and accelerator pedal

assembly is below 5Ω.


4

Test whether resistance between pins of signal voltage

circuit between ECM and accelerator pedal assembly is

below 5Ω.


5 Test whether resistance between signal circuit terminals

of accelerator pedal position sensor 1 and 2 is infinite. - Go to Step 7 Go to Step 6

6

Check corresponding circuit for failures of open circuit,

over-high resistance and short circuit and repair. Clear

trouble code with malfunction diagnosis instrument and

re-read the trouble code to ensure the failure is cleared.

- - -



6.4C.4.34 DTC P0627 Fuel pump relay circuit open

Circuit description

As long as engine is started or in operation, ECM will supply ignition voltage to fuel pump relay coil side. As long as

engine is started or in operation, ECM will start fuel pump relay and receive ignition system reference pulse. If no ignition

system reference pulse is received, ECM will close fuel pump.

Fuel pump relay control circuit is fitted with a feedback circuit connected to the inside of ECM. ECM determines on the

basis of monitoring voltage whether control circuit is open, short to the bonding circuit or to the voltage. When the

instruction is connected and if ECM detects that control circuit voltage is lower than the predetermined voltage, DTC will

be configured.


Open circuit detected by ECM internal hardware








Aids for diagnosis

If ECM wiring harness connection or component wiring harness connector needs to be detected in the test, a

connector should be used to test the adapter assembly.

If it’s intermittent failure, while monitoring the circuit condition in the output drive module (ODM) data sheet with a

malfunction diagnosis, move related wiring harness and connectors. If there is problem with the circuit or the

connection, circuit condition parameter will change from “OK” to “Fault”.

See “Intermittent failure” for intermittent failure.

Test description

The following serial numbers are corresponding with the procedure numbers.

This procedure ensures that the ECM supplies voltage to fuel pump relay.


DTC P0627 Fuel pump relay circuit open

Step Action Yes No

1 Did you perform the “Check of diagnostic system - vehicle”? Go to Step 2

Go to "Check of

diagnostic system –

vehicle" in "Vehicle

DTC information"

2

Additional DTCs may set when using the fuel pump output

control.


2. With a scan tool, command the fuel pump "ON" and "OFF".

Does the fuel pump relay turn ON and OFF with each

command?


3

1. Observe the "Freeze Frame/Failure Records" for this DTC.



4. Operate the vehicle within the "Conditions for running the

DTC". You may also operate the vehicle within the

conditions that you observed from the "Freeze



Go to Step 4 Go to "Diagnostic

aids"

4


2. Disconnect the fuel pump relay.


4. Probe the control circuit of the fuel pump relay with a test

lamp connected to a good ground.

5. Command the fuel pump relay "ON" and "OFF" with a scan

tool.

Does the test lamp turn ON and OFF?


5

Test the control circuit of the fuel pump relay for a short to

ground.



6 Replace fuel pump relay.

Is the replacement complete? Go to Step 8 Go to Step 7

7 Replace the ECM.


8





DTC". You may also operate the vehicle within the

conditions that you observed from the "Freeze






Go to "DTC list -


DTC information"

System OK


6.4C.4.35 DTC P0628 Fuel pump relay circuit short to earth

Circuit description




Fuel pump relay control circuit is fitted with a feedback circuit connected to the inside of ECM.ECM determines on the


instruction is connected and if ECM detects that control circuit voltage is lower than the predetermined voltage, DTC will

be configured.


Circuit short to earth detected by ECM internal hardware







Aids for diagnosis







Test description


This procedure ensure that the ECM supplies voltage to fuel pump relay.


DTC P0628 Fuel pump relay circuit short to earth

Step Action Yes No

1 Did you perform the “Check of diagnostic system - vehicle”? Go to Step 2

Go to "Check of

diagnostic system –


DTC information"

2

Additional DTCs may set when using the fuel pump output control.


2. With a scan tool, command the fuel pump "ON" and "OFF".

Does the fuel pump relay turn ON and OFF with each command?


3





DTC". You may also operate the vehicle within the conditions

that you observed from the "Freeze Frame/Failure Records".



aids"

4


2. Disconnect the fuel pump relay.


4. Probe the control circuit of the fuel pump relay with a test lamp


5. Command the fuel pump relay "ON" and "OFF" with a scan

tool.

Does the test lamp turn ON and OFF?


5 Test the control circuit of the fuel pump relay for a short to ground.

Did you find and correct the condition? Go to Step 8 Go to Step 7


Is the replacement complete? Go to Step 8 Go to Step 7

7 Replace the ECM.


8











Go to "DTC list -

vehicle" in

"Vehicle DTC

information"

System OK


6.4C.4.36 DTC P0629 Fuel pump relay circuit short to power

Circuit description




Fuel pump relay control circuit is fitted with a feedback circuit connected to the inside of ECM. ECM determines on the


instruction is connected and if ECM detects that control circuit voltage is higher than the predetermined voltage, DTC

will be configured.







If there is no fault after 3 continuous driving cycles, the malfunction indicating lamp will be off.



Aids for diagnosis







Test description


This procedure ensure that the ECM supplies voltage to fuel pump relay.


DTC P0629 Fuel pump relay circuit short to power

Step Action Yes No

1 Did you perform the "Check of diagnostic system - vehicle"? Go to Step 2

Go to "Check of diagnostic system – vehicle" in "Vehicle DTC information"

2

Important: Additional DTCs may set when using the fuel pump output control. 1. Turn the ignition switch to the ON position with the engine

OFF. 2. With a scan tool, command the fuel pump "ON" and "OFF". Does the fuel pump relay turn ON and OFF with each command?


3

1. Observe the "Freeze Frame/Failure Records" for this DTC. 2. Switch off the ignition for 30 seconds. 3. Start the engine. 4. Operate the vehicle within the "Conditions for running the

DTC". You may also operate the vehicle within the conditions that you observed from the "Freeze Frame/Failure Records".



aids"

4

1. Turn OFF the ignition. 2. Disconnect the fuel pump relay. 3. Turn the ignition switch to the ON position with the engine

OFF. 4. Probe the control circuit of the fuel pump relay with a test

lamp connected to a good ground. 5. With a scan tool, command the fuel pump "ON" and "OFF". Does the test lamp turn ON and OFF when commanded?


5

1. Connect a test lamp between the control circuit of the fuel pump relay and the ground circuit of the fuel pump relay.

2. With a scan tool, command the fuel pump relay "ON" and "OFF".

Does the test lamp turn ON and OFF when commanded?


6 Test the control circuit of the fuel pump relay for a short to voltage or an open. Did you find and correct the condition?


7 Test for shorted terminals and for poor connections at the fuel pump relay. Did you find and correct the condition?


8 Test for shorted terminals and for poor connections at the engine control module (ECM). Did you find and correct the condition?


9 Repair the open ground circuit of the fuel pump relay. Is the repair complete?

Go to Step 12 -


Is the replacement complete? Go to Step 12 -

11 Replace the ECM.


12

1.Use a scan tool to clear all DTCs.

2.Switch off the ignition for 30 seconds.

3.Start the engine.

4.Operate the vehicle within the "Conditions for running the DTC".

You may also operate the vehicle within the conditions that you

observed from the "Freeze Frame/Failure Records".





Go to "DTC list -

vehicle" in

"Vehicle DTC

information"

System OK


6.4C.4.37 DTC P0201 1st cylinder fuel injector circuit open

Circuit description

The two pins connected to the 1st cylinder fuel spray nozzle are respectively 12V supply voltage (main relay terminal pin

ZK10) and the control terminal input (ECU pin B_L4). 1st cylinder fuel spray nozzle in the system is driven by a drive

chip which can realize self diagnosis of driver stage through comparing switching signal from CPU and actual potential

of driver stage output terminal and can also send the fault information to fault diagnostic module inside the CPU.










Aids for diagnosis

The following may cause intermittent situations:

Important note: remove all debris from joint surfaces before repairing components. Check joint gasket before diagnosis

or replacement of components. Ensure the gasket is correctly installed. The gasket can prevent pollutants from entering.

Poor terminal connection-check the wiring harness for loosening terminals, mismatching, damaged keeper,

inappropriate or damaged shape as well as failed connection with the wire. Test whether the tension is suitable with

corresponding matching terminals.

Damaged wiring harness-check if wiring harness is damaged. If no wiring harness failure is detected, watch the display

on the scanning instrument while moving connectors and wiring harness related with the sensor.If the display shows

changes, it indicates failure in this section.

Is ECU and engine ground joint reliable and clean? If DTC is determined as intermittent failure, by referring to failure

records the last time when the DTC is set can be determined.


DTC P0201 1st cylinder fuel injector circuit open


1. Is "Check of powertrain on-board diagnostic system"

performed? - Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Handle the vehicle in accordance with trouble code

operating condition.

2. Connect the scanning instrument.

3. Monitor trouble code information with the scanning

instrument.

Is DTC P0201 indicated by the instrument the current

trouble code?

- Go to Step 3

Go to

"Diagnostic

aids"

3


2. Disconnect plug of fuel spray nozzle 1.

3. Turn on the ignition switch.

4. Measure the voltage between wiring harness plug of

1st cylinder fuel spray nozzle (brown/red pin) and the

earth with a multimeter.

Is the measured voltage within specified range?

3.7-.4.4 V Go to Step 4 Go to Step 6

4.

Connect a test lamp between 1st cylinder fuel spray

nozzle wiring harness plug pin (red line) and the earth.

When battery voltage is normal, can test lamp reach

normal brightness?


5. Test the fuel spray nozzle. See “Fuel spray nozzle coil

test”.Is the test in line with the specified value?

11-13 Ω

at 20°C Go to Step 6 Go to Step 7

6

Check whether 1st cylinder fuel spray nozzle circuit is

short, break, whether there is a high resistance in the

wiring harness and whether there is poor connection

between ECU terminal and fuel spray nozzle terminal

plug pin.



7 Replace the fuel spray nozzle.

Is replacement finished? - Go to Step 9 -

8 Replace ECU.


9.

1. Clear DTC.


operating conditions and monitor failure information

with the scanning instrument. Is DTC P0201

indicated by the instrument the current trouble code?



6.4C.4.38 DTC P0202 2nd cylinder fuel injector circuit open

Circuit description

The two pins connected to the 2nd cylinder fuel spray nozzle are respectively 12V supply voltage and the control

terminal input (ECU pin B_K4). 2nd cylinder fuel spray nozzle in the system is driven by a drive chip which can realize

self diagnosis of driver stage through comparing switching signal from CPU and actual potential of driver stage output

terminal and can also send the fault information to fault diagnostic module inside the CPU.










Aids for diagnosis








on the scanning instrument while moving connectors and wiring harness related with the sensor. If the display shows





DTC P0202 2nd cylinder fuel injector circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2



2. connect the scanning instrument.


instrument.


trouble code?

- Go to Step 3

Go to

"Diagnostic

aids"

3





2nd cylinder fuel spray nozzle (blue/red pin) and the

earth with a multimeter. Is the measured voltage

within specified range?

3.7-.4 .4V Go to Step 4 Go to Step 6

4.

Connect a test lamp between 2nd cylinder fuel spray



normal brightness?


5. See “Fuel spray nozzle coil test”.

Is the test in line with the specified value?

11-13 Ω at


6

Check whether 2nd cylinder fuel spray nozzle circuit is




plug pin.





8 Replace ECU.


9.

1. Clear DTC.



with the scanning instrument.


trouble code?



6.4C.4.39 DTC P0203 3rd cylinder fuel injector circuit open

Circuit description

The two pins connected to the 3rd cylinder fuel spray nozzle are respectively 12V supply voltage and the control

terminal input (ECU pin B_M4). 3rd cylinder fuel spray nozzle in the system is driven by a drive chip which can realize

self diagnosis of driver stage through comparing switching signal from CPU and actual potential of driver stage output



● Open circuit detected by ECM internal hardware.


● It will enter into failure memory immediately a malfunction arises.

● Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 1 continuous driving cycle.


● If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.


● Fault code can be cleared with a malfunction diagnosis instrument.

Aids for diagnosis













DTC P0203 3rd cylinder fuel injector circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2



2. connect the scanning instrument.


instrument.


trouble code?

- Go to Step 3

Go to

"Diagnostic

aids"

3





3rd cylinder fuel spray nozzle (purple/brown pin) and

the earth with a multimeter.

Is the measured voltage within specified range?

3.7-4.4 V Go to Step 4 Go to Step 6

4.

Connect a test lamp between 3rd cylinder fuel spray



normal brightness?



test”. Is the test in line with the specified value?

11-13 Ω


6

Check whether 3rd cylinder fuel spray nozzle circuit is




plug pin.





8 Replace ECU.


9.

1. Clear DTC.





trouble code?



6.4C.4.40 DTC P0204 4th cylinder fuel injector circuit open

Circuit description

The two pins connected to the 4th cylinder fuel spray nozzle are respectively 12V supply voltage and the control terminal

input (ECU pin B_M3). 4th cylinder fuel spray nozzle in the system is driven by a drive chip which can realize self

diagnosis of driver stage through comparing switching signal from CPU and actual potential of driver stage output



Open circuit detected by ECM internal hardware.








Aids for diagnosis



or replacement of components.Ensure the gasket is correctly installed.The gasket can prevent pollutants from entering.

Poor terminal connection - check the wiring harness for loosening terminals, mismatching, damaged keeper,



Damaged wiring harness - check if wiring harness is damaged. If no wiring harness failure is detected, watch the display



Is ECU and engine ground joint reliable and clean?If DTC is determined as intermittent failure, by referring to failure



DTC P0204 4th cylinder fuel injector circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2



2. Connect the scanning instrument.


instrument.


trouble code?

- Go to Step 3

Go to

"Diagnostic

aids"

3





4th cylinder fuel spray nozzle (blue/yellow pin) and

the earth with a multimeter. Is the measured

voltage within specified range?

3.7-4.4 V Go to Step 4 Go to Step 6

4.

Connect a test lamp between 4th cylinder fuel spray



normal brightness?



test”. Is the test in line with the specified value?

11-13 Ω


6

Check whether 4th cylinder fuel spray nozzle circuit is




plug pin.





8 Replace ECU.


9.

1. Clear DTC.



with the scanning instrument. Is DTC P0204

indicated by the instrument the current trouble code?



6.4C.4.41 DTC P0261, P0264, P0267 and P0270 Cylinder 1/2/3/4 fuel injector circuit short to

earth

Circuit description

ECM controls each cylinder fuel injector pulse count. Ignition voltage is supplied to the fuel injector. ECM control of each

injector is realized through making control circuit go through a solid-state device bonding known as actuator. ECM

monitors each actuator state. If voltage of actuator under instruction state detected by the ECM is too low, DTC P0261,

P0264, P0267 and P0270 will be configured.










Aids for diagnosis













DTC P0261, P0264, P0267 and P0270 Cylinder 1/2/3/4 fuel injector circuit short to earth

Step Action Yes No

1 Did you perform the check of powertrain on-board diagnostic

system? Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Use the scan tool in order to clear the DTCs.

2. Crank the engine or start the engine.

Are the DTC P0261, P0264, P0267 or P0270 set?


3









4

Turn off the ignition switch and disconnect the multiphase wiring

harness connector of the corresponding fuel injector. Turn on the

ignition switch and carry out a load test between the

corresponding control circuit of fuel injector and the ground. Is the

voltage between 3.4V and 4.4V.


5

Turn off the ignition switch and measure the resistance between

the corresponding control circuit of fuel injector and the ground.

Check whether the digital multi-meter shows the open loop (OL).


6

Important: The ECT sensor must be 10-32 °C (50-90 ° F) . Test

whether the resistance between the corresponding control circuit

of fuel injector and the ignition voltage circuit of fuel injector is

12-16 Ω.


7 Measure whether the resistance between the terminals of fuel

injector is 11-13Ω. Go to Step 13 Go to Step 12

8

Repair the open circuit to ground or short circuit fault condition in

the ignition voltage circuit of the fuel injector.

Is the problem fixed?

Go to Step 14 -

9

Test for a short to ground or an open/too high resistance on the

control circuit of fuel injector. Tests for a short to voltage on the

control circuit of fuel injector.

Go to Step 14 -

10 Repair the short to ground on the control circuit of fuel injector. Go to Step 14 -

11

Test for an open/too high resistance or a short to ground on the

control circuit of fuel injector. Test for a short between the control

circuit of fuel injector or the ignition voltage circuit of fuel injector.

Go to Step 14 -

12 Test or replace the fuel injector. Go to Step 14 -

13 Replace the ECM. Go to Step 14 -

14









15 Check if there is any DTC that has not been diagnosed with a

malfunction diagnosis instrument?

Go to "DTC list

- vehicle" System OK


6.4C.4.42 DTC P0262, P0265, P0268 and P0271 Cylinder 1/2/3/4 fuel injector circuit short to

power

Circuit description

ECM controls each cylinder fuel injector pulse count. Ignition voltage is supplied to the fuel injector. ECM control of each

injector is realized through making control circuit go through a solid-state device bonding known as actuator. ECM

monitors each actuator state. If voltage of actuator under instruction state detected by the ECM is too low, DTC P0262,

P0265, P0268 and P0271 will be configured.


Circuit short to power detected by ECM internal hardware








Aids for diagnosis













DTC P0262, P0265, P0268 and P0271 Cylinder 1/2/3/4 fuel injector circuit short to power

Step Action Yes No

1 Did you perform the check of powertrain on-board diagnostic system? Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2



Are the DTC P0262, P 0265, P0268 or P0271 set?


3




4. Operate the vehicle within the "Conditions for running the DTC".

You may also operate the vehicle within the conditions that you

observed from the "Freeze Frame/Failure Records".



aids"

4


2. Remove the fuel injector sight shield.

3. Connect the injector test lamp between the control circuit and the

ignition voltage circuit of the fuel injector.


Does the test lamp flash?


5 Does the test lamp remain illuminated at all times? Go to Step 8 Go to Step 6

6 Test the control circuit of fuel injector for a short to ground.


7 Check for an intermittent and for a poor connection at the fuel injector.

Did you find and correct the condition? Go to Step 8 -

8 Test for an intermittent and for a poor connection at the ECM.


9

Repair the short-to-ground in the ignition voltage circuit of the

odd-numbered fuel injectors.

Is the repair complete?

Go to "DTC list -

vehicle" System OK


6.4C.4.43 DTC P0300 Repeated misfire, P0301 Misfire 0 (cylinder 1), P0302 Misfire 3 (cylinder

2), P0303 Misfire 1 (cylinder 3), and P0304 Misfire 2 (cylinder 4)

Description:

Misfire refers to the situation that combustion process in the cylinder cannot be interrupted or combustion cannot be

started because ignition energy cannot be effectively released by engine ignition system in the cylinder (failed ignition),

or there is deviation in fuel charge (deviation in gas mixture concentration), or cylinder compression pressure is too low

or due to other reasons. This will lead to the exceeded emission limits or damage of catalyst for overheat. As far as OBD

diagnostic test is concerned, it indicates that the number of misfires has exceeded the specified limit and the system will

take it as fault of misfire.


Engine speed is between 600 ~ 4000 RPM

Engine load is greater than zero

Engine temperature is greater than -7.5 ℃

Atmospheric pressure is greater than 750 hbar

There is no bad circuit

Under the above conditions, fire rate is more than rated value.









DTC P0300-P0304 Multi-cylinder, cylinder 1, 2, 3 and 4 misfire fault

Step Action Yes No

1 Leave the vehicle still for some time to let engine water temperature

and fuel temperature to fall to room temperature or lower.

2 Remove the catalyst converter, check the carrier for signs of sintering

and reinstall the original converter. Go to Step 3 Go to Step 4

3 Is the misfire of the system serious without being accidental or

misjudgment? Go to Step 4

4

Check whether connection between each cylinder ignition high-tension

wire and the spark plug and ignition coil is loose and whether connector

between ignition high-tension wire and ignition coil is damaged or aging

or short circuit to vehicle body or the engine. Remove the spark plug

and check whether there is grease stain, black outlook or carbon

deposit and whether spark plug clearance is normal (the spark plug

shall be of the same specification of the original factory). The above

phenomena may lead to misfire. (Refer to checking methods of ignition

system malfunction).


5 Replace the above fault parts related with the ignition system. Go to Step 6

6 Start the engine to see whether engine idling runs stable. Go to Step 7 Go to Step 9

7 After engine flame-out and ignition switch turned to “ON”, connect

malfunction diagnosis instrument and clear related trouble code.

8

Multiple ways can be used to briefly distinguish misfire phenomenon of

the vehicle. Read freeze frame recorded when misfire occurs by the

malfunction diagnosis instrument and drive the vehicle under the same

operating mode according to related information to see whether misfire

will occur again. When the vehicle steadily accelerates to 4000rpm from

low idle coasting state at gear 3, see whether there is obvious vibration

caused by misfire in the acceleration. When the vehicle moves on the

smooth road (it may go with different gear or speed) with constant

speed for some time, see whether the fault lamp blinks. If there is no

blinking, stall the engine and wait for system main relay to be

disconnected and then restart the engine and drive on the smooth road

(it may go with different gear or speed) with constant speed for some

time to see whether the fault lamp will be lit.


9 If misfire is not caused by the ignition system, fuel injection system fault

may be the cause.

10

Check fuel injector and system fuel pressure (see checking methods of

system fuel pressure). If they are normal, check the steam filter and fuel

pump to see whether they function well.


11 Misfire can be caused by engine fuel channel. Replace related

components with fault. Go to Step 12

12 Repeat step 8 to see whether fault lamp is lit or blinking. Go to Step 13 Go to Step 14

13 If engine misfire is not caused by the fuel channel, mechanical state of

the engine shall be examined.

14 If there are signs of sintering in the original catalyst converter, replace it.


6.4C.4.44 DTC P0325 Knock sensor failure (signal pickup fault)

Description:

Knock sensor is used to detect engine knock. When knock signal (KS) is received by TCM and ECM, ignition timing will

be delayed. KS will generate an alternating voltage signal. Under conditions of no knock, KS circuit signal will assume

the form of an alternating voltage with reference voltage as 0.007V. Amplitude and frequency of KS voltage signal

depends on the intensity of the knock. ECM consists of a non-replaceable knock filter module, that is, the signal and

noise enhancing filter (SNEF) module. Filter module in ECM determines whether there is a knock through comparison of

KS circuit and background noise voltage signal. ECM resists any false knock signal through the normal engine noise

standard of the current noise channel. The normal engine noise varies with engine speed and load. When an unusual

background noise low voltage signal is detected by the ECM.


Circuit short to power detected by ECM internal hardware









P0325 Knock sensor failure

Step Action Yes No

1. Is "Check of powertrain on-board diagnostic system" performed? Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2

Note: if engine knock is heard, repair engine mechanical failures before

perform this diagnosis.

1. Handle the vehicle in accordance with trouble code operating

condition.

2. For DTC P0325, monitor specific information of the DTC with a

scanning instrument until the test is in operation.

Does the scanning instrument indicate DTC to show failed ignition?


aids"

3

1. Disconnect the ECM and knock sensor.

2. Test whether engine knock sensor circuit is open or short to earth.

Whether faults are detected and repaired?


4 Check for poor connection of knock sensor circuit terminals. Is failure

detected and resolved? Go to Step 7 Go to Step 5

5 Replace the knock sensor.

Is replacement finished? Go to Step 7 -

6 Replace ECU.


7

1. Clear DTC.


conditions and monitor failure information with the scanning

instrument.

Is DTC P0325 indicated by the instrument the current trouble code?

Go to Step 2 System OK


6.4C. 4.45 DTC P0325 knock sensor fault (signal value fault)

Description: Knock sensor is used to detect engine knock. When knock signal (KS) is received by TCM and ECM, ignition timing will

be delayed. KS will generate an alternating voltage signal. Under conditions of no knock, KS circuit signal will assume

the form of an alternating voltage with reference voltage as 0.007V. Amplitude and frequency of KS voltage signal

depends on the intensity of the knock. ECM consists of a non-replaceable knock filter module, that is, the signal and

noise enhancing filter (SNEF) module. Filter module in ECM determines whether there is a knock through comparison of

KS circuit and background noise voltage signal. ECM resists any false knock signal through the normal engine noise

standard of the current noise channel. The normal engine noise varies with engine speed and load. When an unusual

background noise low voltage signal is detected by the ECM.


Engine water temperature is greater than 65.25 V

Intake flow rate is greater than 202 mg/str

Engine speed is greater than 1504 RPM









P0325 knock sensor fault Step Action Yes No

1. Is "Check of powertrain on-board diagnostic system" performed? Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2

Note: if engine knock is heard, repair engine mechanical failures before

perform this diagnosis.


condition.

2. For DTC P0325, monitor specific information of the DTC with a

scanning instrument until the test is in operation.

Does the scanning instrument indicate DTC to show failed ignition?


aids"

3

1. Disconnect the ECM and knock sensor.

2. Test whether engine knock sensor circuit is open or short to earth.

Whether faults are detected and repaired?


4 Check for poor connection of knock sensor circuit terminals. Is failure

detected and resolved? Go to Step 7 Go to Step 5

5 Replace the knock sensor.


6 Replace ECU.


7

1.Clear DTC.

2.Handle the vehicle in accordance with trouble code operating

conditions and monitor failure information with the scanning instrument.

Is DTC P0325 indicated by the instrument the current trouble code?



6.4C.4.46 DTC P0336 Inappropriate/No/Losing synchronization of crankshaft sensor signal

Circuit description

58X(58 teeth deficiency) reference point signal is generated by crankshaft position (CKP) sensor. When the crankshaft

spins, 58X will produce crankshaft pulses to drive the TCM and ECM to calculate engine speed and crankshaft position

with this signal. ECM continuously monitors pulse number on the 58X reference point circuit and compare with camshaft

position sensor signal pulse number received. When ECM receives and detects incorrect pulse number on the 58X

reference point circuit, P0336 trouble code will be configured.


Signal received by ECM does not conform the normal value.








Aids for diagnosis

Intermittent pulses may be caused by poor terminal connection, wornout insulant or damaged wire inside the covered

cable. Check:

Poor terminal connection - check the wiring harness for loosening terminals, mismatching, damaged keeper,

inappropriate or damaged shape as well as failed connection with the wire.

Damaged wiring harness- Check for damaged wiring harness; if no fault, disconnect ECM and turn on the ignition

switch; move connectors and wires connected with ECM and observe the voltmeter which has been connected to

the ECM wiring harness 58X reference point circuit. Changes on the voltmeter indicate the fault location.

Review of the mile distance record of the vehicle since diagnosis failure will help determine frequency of the

configuration of the DTC. This will also help with the conditions needed to confirm the diagnosis.


DTC P0336 Inappropriate/No/Losing synchronization of crankshaft sensor signal



diagnostic system? -- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2 Attempt to start the engine.

Can the engine be started? -- Go to Step 3

Go to “Engine

crankshaft

idling”

procedure

3

1. Review and record the failure information.

2. Clear the DTC P0336.

3. Start the engine and let it idle for 1 minute.

4. Observe the DTC.

Is the DTC P0336 set?

-- Go to Step 4

Go to

"Diagnostic

aids"

4

1. Disconnect the ECM and the crankshaft position

(CKP) sensor.

2. Test the ECM and the CKP circuit interface for an

open or a short to ground.

Did you find the condition?

-- Go to Step 5 Go to Step 6

5

Repair the open voltage or too low voltage of 58 X

reference circuit between the ECM terminal and the CKP

terminal.


-- Go to Step 11 --

6

1. Reconnect the ECM and the CKP.

2. Measure pin B_H3 or B_J2 with an OSC and

observe changes of the OSC wave pattern while the

engine is in operation.

Is there sine wave output from the OSC?


7

Test the interface of crankshaft position sensor and

replace the terminal when necessary.

Is the replacement necessary?


8 Replace the crankshaft position sensor.

Is the replacement complete? -- Go to Step 11 --

9

Test the ECM interface and replace the terminal

when necessary.

Is the replacement necessary?


10 Replace the ECM.

Is the replacement complete? -- Go to Step 11 --

11


2. Start the engine and idle at normal operating

temperature.


the DTC as specified in the supporting text.

Does the scan tool indicate that the diagnostic has run

and passed?


12

Test for the additional DTCs that have not been

diagnosed.

Are there any transferred DTCs that have not been

diagnosed?

--

Go to

corresponding

DTC table

System OK


6.4C.4.47 DTC P0315 Flywheel self-adaption cycle time at limit state

Circuit description

58X reference signal is generated by crankshaft position (CKP) sensor. Every circle of the crankshaft generates 58

crankshaft pulses. ECM will calculate engine speed and crankshaft position with the 58X reference signal. ECM

continuously monitors pulse number on the 58X reference circuit and compare it with camshaft position sensor signal

pulse number received. If pulse number on the 58X reference circuit received by the ECM is incorrect, DTC P0315 will

be configured.





Malfunction indicating lamp will not be lit.




Aids for diagnosis

Intermittent faults may be caused by poor connection, wornout insulant or broken wire inside the covered cable. Check

for the following situations:

Poor connection- check for poor connection between ECM wiring harness and connectors, broken keeper,

deformed or damaged terminals and poor connection between terminals and wire.

Damaged wiring harness - check if wiring harness is damaged. If the wiring harness looks normal, disconnect the

ECM and turn on ignition switch. While moving connectors and wires related with ECM, observe the voltmeter

which has been connected to 58X reference circuit on the ECM wiring harness connector. Changing voltage can

indicate the location of the fault.

Refer to vehicle driving distance since the last failed diagnosis test in the “failure records”. It will be of help in

determining the occurrence frequency of faults leading to the configuration of this DTC. It’s helpful for the diagnosis

of this fault.


DTC P0315: Flywheel self-adaption cycle time at limit state


1

Perform the “European on-board diagnostic (EOBD)

system Check”.

Is the system check complete?

– Go to Step 2

Go to "Check of

on-board

diagnostic

system"

2 Try to start the engine.

Can the engine be started? – Go to Step 3

Refer to “Engine

rotates, but not

runs”

3


2. Connect the malfunction diagnosis instrument to the

data link connector (DLC).

3. Keep the engine shut and connect the ignition switch.

4. Refer to and record in “Failure Records”.

5. Clear the DTC.

6. Start the engine and run in idle for 1 minute.

Is DTC P0315 set?

– Go to Step 4

Go to

"Diagnostic

aids"

4

1. Remove the crankshaft.

2. Check for appearance and gear problems of the

crankshaft.

Is any problem detected?

– Go to Step 5 Go to Step 6

5 Replace the crankshaft.

Is replacement finished? – System OK –

6


2. Replace the ECM.

Is replacement finished?

– Go to Step 7 –

7


instrument.

2. Start the engine and idle at normal working

temperature.

3. In the state of running DTC, handle the vehicle.

Is it indicated on the malfunction diagnosis instrument

that the diagnosis is running and passed?


8 Check whether other DTC is set.

Is there any DTC that has not been diagnosed? –

Go to applicable

DTC table System OK


6.4C.4.48 DTC P0373 Incorrect signal/signal cycle of crankshaft teeth

Circuit description

58X reference signal is generated by crankshaft position (CKP) sensor. Every circle of the crankshaft generates 58

crankshaft pulses. ECM will calculate engine speed and crankshaft position with the 58X reference signal. ECM

continuously monitors pulse number on the 58X reference circuit and compare it with camshaft position sensor signal

pulse number received. If pulse number on the 58X reference circuit received by the ECM is incorrect, P0373 will be

configured.







When 40 consecutive pre-heating cycles run fault-freely,trouble code will be cleared.

Trouble code can be cleared with a malfunction diagnosis instrument.

Aids for diagnosis



Poor connection- check for poor connection between ECM wiring harness and connectors, broken keeper,

deformed or damaged terminals and poor connection between terminals and wire.

Damaged wiring harness - check if wiring harness is damaged. If the wiring harness looks normal, disconnect the

ECM and turn on ignition switch. While moving connectors and wires related with ECM, observe the voltmeter

which has been connected to 58X reference circuit on the ECM wiring harness connector. Changing voltage can

indicate the location of the fault.


determining the occurrence frequency of faults leading to the configuration of this DTC. It’s helpful for the diagnosis

of this fault.


DTC P0373 Incorrect signal of crankshaft teeth


1

Perform the “European on-board diagnostic (EOBD)

system Check”.


– Go to Step 2

Go to "Check of

on-board

diagnostic

system"

2 Try to start the engine.

Can the engine be started? – Go to Step 3

Refer to “Engine

rotates, but not

runs”

3


2. Connect the malfunction diagnosis instrument to the

data link connector (DLC).

3. Keep the engine shut and connect the ignition switch.

4. Refer to and record in “Failure Records”.

5. Clear the DTC.

6. Start the engine and run in idle for 1 minute.

Is DTC P0373 set?

– Go to Step 4

Go to

"Diagnostic

aids"

4

1. Remove the crankshaft.

2. Check for appearance and gear problems of the

crankshaft.



5 Replace the crankshaft.

Is replacement finished? – System OK –

6


2. Replace the ECM.



7


instrument.


temperature.

3. In the state of running DTC, handle the vehicle.

Is it indicated on the malfunction diagnosis instrument

that the diagnosis is running and passed?



Is there any DTC that has not been diagnosed? –

Go to applicable

DTC table System OK


6.4C.4.49 DTC P0341 Inappropriate intake camshaft position sensor signal / intake camshaft

position sensor signal cycle out-of-limit / intake camshaft position sensor with problematic

sysnchronization

Circuit description

Camshaft position sensor can be used to monitor and link the crankshaft with the camshaft for ECM to judge which

cylinder to inject fuel. For each crankshaft position, polarity of camshaft position sensor signal can only be changed

once.


The camshaft tooth’s cycle is less than 0.5ms.





After 40 constant touble-free warming-up cycles, remove the trouble.


Aids for diagnosis

Check and confirm unusual background noises with a diagnosis instrument.

Factors that are suspected of causing engine noise can be fully summarized as follows:

Loosening terminal;


Broken keeper

Deformed terminal;

Damaged terminal;

Poor connection between wire and terminal;

Physical damage of wiring harness.


DTC P0341 Inappropriate intake camshaft position sensor signal



diagnostic system? -- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Turn the ignition switch to the LOCK position.

2. Disconnect the camshaft position sensor terminal.

3. Test for the misconnection of terminals and pins.

Did you find a problem?


3


2. Disconnect the ECM terminal.

3. Check for the bent ECM pins and terminals or the

damaged pins.

4. When related terminals and wire are in the

connected state, check whether wires between B_

C3, B_ M2 and B_L1 of corresponding wiring

harness of camshaft position sensor are open, short

to earth or power.


4


2. Repair or replace the wires or terminals.

3. Clear the DTCs on the ECM.

4. Run the engine.

5. Complete the check of the diagnostic system.

Is the preparation complete?

-- System OK --

5


2. Replace the camshaft position sensor.

3. Clear all the DTCs on the ECM.

4. Run the engine.


Is the DTCP0341 reset?

-- System OK Go to Step 6

6

1. Replace the ECM.

2. Run the engine.



-- Go to Step 7 --

7


2. Start the engine and allow it to idle at the normal

operating temperature.


the DTC as specified in the supporting text.

Does the scan tool indicate that this diagnostic has run

and passed?

-- Go to Step 8 --

8

Test for the additional DTCs that have not been

diagnosed.

Are there any transferred DTCs that have not been

diagnosed?

--

Go to

corresponding

DTC table

System OK


6.4C.4.50 DTC P0351, P0352, P0353, P0354 ignition coil 1 open circuit/ignition coil 2 open

circuit/ignition coil 3 open circuit/ignition coil 4 open circuit

Circuit description

ECM provides ground connection for the electronic ignition timing. When the grounded circuit of primary ignition coil is

cut off by ECM, the magnetic field generated by the coil will disappear. In the disappearing process of the magnetic field,

voltage will be generated in secondary coil which will drive spark plug to strike sparks. Monitor circuit between ECM and

the electronic ignition system to see whether it’s open, or short to voltage or low voltage.










Aids for diagnosis

Before using the diagnosis instrument, check and eliminate abnormal engine noises. Thorough check of the suspicious

circuit reported to have caused engine noise shall be conducted to see whether there are the following situations:

Terminals come off.

Mismatch;

Broken keeper;

Deformation;

Damaged terminal;


There is substantive damage of wiring harness.


DTC P0351, P0352, P0353, P0354 Ignition coil circuit open


1

Perform the "Check of European on-board diagnostic

(EOBD) system".


– Go to Step 2

Go to "Check of

on-board

diagnostic

system"

2

Check for a faulty connection or a damaged Terminal at

the ignition coil.



3


the ECM connector.



4

1. Turn the ignition to the LOCK position

2. Disconnect the ECM.

3. Check the ignition control circuit for a short to ground.



5

Check the ignition control circuit for a short to battery

voltage.



6 Check for an open in the ignition control circuit.

Did you find a problem? – Go to Step 8 Go to Step 7

7 Replace the ECM.

Is the replacement complete? – Go to Step 8 –

8





the DTC as specified in the supporting test.


and passed?


9 Check if any additional DTCs are set.

Are any DTCs displayed that have not been diagnosed? –

Go to applicable

DTC table System OK


6.4C.4.51 DTC P2300, P02303, P02306, P2309 1 cylinder/2 cylinder /3 cylinder/4 cylinder

ignition coil short to earth

Circuit description




the electronic ignition system to see whether it’s open, or short to voltage and power.










Aids for diagnosis



Terminals come off.

Mismatch;

Broken keeper;

Deformation;

Damaged terminal;




DTC P2300, P02303, P02306, P2309 1 cylinder/2 cylinder /3 cylinder/4cylinder ignition coil short to earth


1


(EOBD) system".


– Go to Step 2

Go to "Check of

on-board

diagnostic

system"

2


the ignition coil.



3


the ECM connector.



4






5


voltage.





7 Replace the ECM.


8







and passed?




Go to applicable

DTC table System OK


6.4C.4.52 DTC P2301, P02304, P02307, P2310 1 cylinder/2 cylinder /3 cylinder/4 cylinder

ignition coil short to power

Circuit description




the electronic ignition system to see whether it’s open, or short to voltage and power.










Aids for diagnosis



Terminals come off.

Mismatch;

Broken keeper;

Deformation;

Damaged terminal;




DTC P2301, P02304, P02307, P2310 1 cylinder/2 cylinder /3 cylinder/4cylinder ignition coil short to power


1


(EOBD) system".


– Go to Step 2

Go to "Check of

on-board

diagnostic

system"

2


the ignition coil.



3


the ECM connector.



4






5


voltage.





7 Replace the ECM.


8







and passed?




Go to applicable

DTC table System OK


6.4C.4.53 DTC P0420 Low catalyst conversion efficiency

Circuit description

The three-way catalyst (TWC) is used to control the emission of hydrocarbon (HC), CO and Nox.Catalyzer in the

converter can facilitate the oxidation of HC and CO in the exhaust gas and convert them into harmless water vapor and

CO2. NOx can also be reduced by converting it into nitrogen. The converter can also store oxygen. ECM can monitor

this process with the heated oxygen sensor (HO2S) in the exhaust gas flow which goes through the TWC. The heated

oxygen sensor (HO2S) will generate an output signal indicating the oxygen storage capability of the catalyzer. This

further shows the capability of effective exhaust gas conversion of the catalyzer. ECM will first wait for the catalyzer to

be heated and wait until the stable state while idling; then it will monitor reaction of the heated oxygen sensor (HO2S)

and at the same time increase and reduce fuel supply in order to monitor catalyzer efficiency. When the catalyzer

functions well, the heated oxygen sensor (HO2S) reacts slower to additional fuel than the oxygen sensor (O2S). When

their reactions are comparatively the same, oxygen storage capability or efficiency of the catalyzer is comparatively low,

and malfunction lamp will be lit.


Average ratio between flow and limit value of catalyst downstream oxygen ＞ 1;

Engine water temperature > 80 ℃

Vehicle speed is between 53 and 83 km/h.

Flow rate of air intake is between 100 and 240 mg/strk;

Model temperature of catalyst is between 500 and 750 ℃








Aids for diagnosis

Catalyzer test may stop with changes in engine load. Engine load (i.e. AC, cooling fan or heater motor) shall not be

changed during catalyzer test. Intermittent faults may be caused by poor connection, wornout insulant or broken wire

inside the covered cable. Thorough check of the suspicious circuit reported to have caused Intermittent faults shall be

conducted to see whether there are the following situations:

Terminals come off.

Mismatch;

Broken keeper;

Deformation;

Damaged terminal;

Poor connection of terminal with the wire.

app:ds:hydrocarbon


DTC P0420 - Low catalyst conversion efficiency

Step Action Yes No

1 Perform “Diagnosis system check-engine control system”.

Is check finished? Go to Step 2

Go to “Diagnosis

system check-engine

control system”.

2

1. Connect malfunction diagnosis instrument


Is component DTC set?

Go to “DTC List”. Go to Step 3

3

Visual check the following components:

Exhaust system leakage;

Back oxygen sensor (HO2S);



4 If necessary, repair the exhaust system.

Is the reparation work finished? Go to Step 6

5

Replace the TWC. See “Replacement of catalyst converter” in

“Engine exhaust system”.

Is the reparation work finished?

Go to Step 6

6


instrument.

2. start the engine and idle at normal working temperature.

3. Operate the vehicle in accordance with descriptions in

setting conditions of DTC.

Is it indicated on the malfunction diagnosis instrument that the

diagnosis is running and passed?



Is any undiagnosed DTC displayed? Go to “DTC List”. System OK


6.4C.4.54 DTC P0444 Canister control valve circuit open

Circuit description

The two pins connected to the canister control valve (EVAP) are respectively 12V main relay power supply （ZK9）and

the control terminal (ECU pin B_Q3).

EVAP driver stage is controlled by a drive chip which can realize self diagnosis of driver stage through comparing

switching signal from CPU and actual potential of driver stage output terminal and can also send the fault information to

fault diagnostic module inside the CPU.


Break circuit is found in ECM internal circuit.

PMW output is between 3.125% and 98.8%.








Aids for diagnosis


1. ECU poor connection-check whether wiring harness connector exists:

Loosening terminal;


Broken keeper



2. Incorrect arrangement of wiring harness-check if wiring harness is damaged. If the wiring harness looks normal,

disconnect ECU and EVAP and connect the ignition switch. Observe the voltmeter connected between EVAP

terminal of canister solenoid control circuit and ECU terminal while moving connectors and wiring harness related

with canister solenoid. If the voltage varies, it indicates fault in this section.


determining the occurrence frequency of faults resulting in the configuration of this DTC. This is helpful to the

diagnosis of this situation.


DTC P0444 Canister control valve circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2.


the DTC.

2. Connect a scan tool.


information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

With a scan tool, command the purge solenoid for

activation.

Does the purge solenoid respond with each command?

-

Go to

"Diagnostic

aids"

Go to Step 4

4.


2. Disconnect the canister solenoid.


4. Connect a test lamp between the EVAP wire

connector 1 pin and the ground.

Does the test lamp reach the normal brightness when the

battery voltage is normal?


5.


2. Use a multi-meter to detect the voltage between the

ECU control circuit of the second pin of canister

solenoid wiring harness connector and the ground.

Is the voltage at the specified value?

About 2.5V Go to Step 7 Go to Step 6

6. Test the EVAP control circuit for a short to ground.


7.

Check the EVAP wiring harness for a short to ground, a

short to power supply, an open or high resistance. Check

for the poor contact of pins at EVAP and ECU end.



8. Replace the purge solenoid. Is the replacement

complete? - Go to Step 10 -

9. Replace the ECU.


10.

1. Clear the DTC with a scan tool.


information.

Is the DTC reset?



6.4C.4.55 DTC P0458 Canister control valve circuit short to earth Circuit description

Two pins connected with canister control valve are 12V main relay power supply（ZK9）and the control terminal (ECU pin

B_Q3). Canister control valve is controlled by driver chip. The chip realizes the self diagnosis of drive stage by comparing the switch signal of CPU and the actual electric potential of output end of drive stage, and can send the diagnosis information to the fault diagnosis module inside CPU. Conditions for setting trouble code A circuit short to earth has been found in ECM internal circuit;

PMW output ＜ 98.8%








Aids for diagnosis



Loosening terminal;


Broken keeper







Refer to vehicle driving distance since the last failed diagnosis test in the “failure records”. It will be of help in determining the occurrence frequency of faults resulting in the configuration of this DTC. This is helpful to the diagnosis of this situation.


DTC P0458 Canister control valve circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Operate on the vehicle in accordance with trouble

code operating condition.


3. Monitor trouble code information with the instrument.

Is it the current trouble code if the instrument indicates

DTC P0458?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

Instruct purging solenoid to act through the malfunction

diagnosis instrument. Does the purging solenoid respond

to each instruction?

-

Go to

"Diagnostic

aids"

Go to Step 4

4




4. Connect a test lamp between EVAP line trap pin 1

and the earth. When battery voltage is normal, can

test lamp reach normal brightness?


5


2. Measure voltage between canister ECU control

circuit of pin 2 of solenoid wiring harness plug and


Is the voltage detected in line with the specified value?


6

Test whether EVAP control circuit is short to earth or

power.



7

Test whether EVAP wiring harness is short to earth or

power, open or with high resistance. Check for poor

connection between EVAP and ECU terminal plug pin.

Is problem detected and resolved?


8 Replace purging solenoid.


9

1. Clear DTC with malfunction diagnosis instrument.

2. Monitor the DTC with the diagnosis instrument. Is

DTC reset?



6.4C.4.56 DTC P0459 Canister control valve circuit short to power

Circuit description

The two pins connected to the canister control valve (EVAP) are respectively 12V main relay power supply （ZK9）and

the control terminal (ECU pin B_NQ3).

EVAP driver stage is controlled by a drive chip which can realize self diagnosis of driver stage through comparing

switching signal from CPU and actual potential of driver stage output terminal and can also send the fault information to

fault diagnostic module inside the CPU.


A circuit short to power has been found in ECM internal circuit;

PMW output ＞3.125%








Aids for diagnosis



Loosening terminal;


Broken keeper；

Deformed or damaged terminal；

Poor connection of terminal with the wire；









DTC P0459 Canister control valve circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2






DTC P0459?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

Instruct purging solenoid to act through the malfunction

diagnosis instrument.

Does the purging solenoid respond to each instruction?

-

Go to

"Diagnostic

aids"

Go to Step 4

4




4. Connect a test lamp between EVAP line trap pin 1

and the earth. When battery voltage is normal, can

test lamp reach normal brightness?


5


2. Measure voltage between canister ECU control

circuit of pin 2 of solenoid wiring harness plug and


Is the voltage detected in line with the specified value?


6 Test whether EVAP control circuit is short to earth or

power. Is failure detected and resolved? - Go to Step 9 Go to Step 7

7

Test whether EVAP wiring harness is short to earth or

power, open or with high resistance. Check for poor

connection between EVAP and ECU terminal plug pin.



8 Replace purging solenoid. Is replacement finished? - Go to Step 9 -

9


2. Monitor the DTC with the diagnosis instrument. Is

DTC reset?



6.4C.4.57 DTC P0691 Cooling fan relay 1 circuit open or short to earth

Circuit description

The 4 pins connected to the cooling fan relay are respectively the 12V power supply terminal, main relay power supply,

control terminal (ECU pin B_L3) and fan terminal.

The drive chip of the cooling fan relay can realize self diagnosis of driver stage through comparing switching signal from

CPU and actual potential of driver stage output terminal and can also send the fault information to fault diagnostic

module inside the CPU.


An open or short circuit to earth is found in ECM internal circuit.








Aids for diagnosis


ECU poor connection-check whether wiring harness connector has the following phenomena:

Loosening terminal;


Broken keeper;



Incorrect arrangement of wiring harness-check if wiring harness is damaged. If the wiring harness looks normal,

disconnect the ECM and turn on ignition switch. While moving connectors and wires related of fan relay, observe the

voltmeter connected to the ECU wiring harness between driver circuit of fan relay and the earth. If the voltage varies, it

indicates location of the fault. Refer to the distance recorded in “Freeze Frame/ Failure Records” since the last failed

diagnosis. It will help determine the formation frequency of DTC setting conditions.


DTC P0691 Cooling fan relay 1 circuit open or short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Stop the engine and turn on the ignition switch.

2. Instruct the connection and disconnection of cooling

fan relay 1 through a scanning instrument.

Does the relay perform every instruction of “Connect” and

“Disconnect”?

-

Go to

"Diagnostic

aids"

Go to Step 3

3


2. Disconnect the relay, turn on the ignition switch but

do not start the engine.

3. Check the supply terminal with a well-grounded test

lamp. Is the test lamp lit?


4

1. connect a test lamp between relay control circuit ans

the supply terminal.

2. Instruct the connection and disconnection of the relay

with a scanning instrument.

Can every instruction turn on or off the test lamp?


5

Check whether relay circuit is short, break, whether there

is a high resistance in the wiring harness and whether

there is poor connection between ECU terminal and relay

terminal plug pin.



6 Replace the relay. Is replacement finished? - Go to Step 8 -

7 Replace ECU. Is replacement finished? - Go to Step 8 -

8

1. Clear DTC.





trouble code?



6.4C.4.58 DTC P0692 Cooling fan relay 1 circuit short to power

Circuit description

The 4 pins connected to the cooling fan relay are respectively the 12V power supply terminal, main relay power supply,

control terminal (ECU pin B_L3) and fan terminal.





A circuit short to power is found in ECM internal circuit.








Aids for diagnosis



Loosening terminal;


Broken keeper;






indicates location of the fault.Refer to the distance recorded in “Freeze Frame/ Failure Records” since the last failed



DTC P0692 Cooling fan relay 1 circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2



fan relay 1 through a scanning instrument. Does

the relay perform every instruction of “Connect” and

“Disconnect”?

-

Go to

"Diagnostic

aids"

Go to Step 3

3





lamp.

Is the test lamp lit?


4







5




terminal plug pin.



6 Replace the relay.


7 Replace ECU.


8

1. Clear DTC.





trouble code?



6.4C.4.59 DTC P0693 Cooling fan relay 2 circuit open or short to earth

Circuit description

The 4 pins connected to the cooling fan relay 2 (controlling the AC condenser fan) are respectively the 12V power

supply terminal, main relay power supply, control terminal (ECU pin B_J3) and fan terminal.





An open or short circuit to earth is found in ECM internal circuit.








Aids for diagnosis



Loosening terminal;


Broken keeper;









DTC P0693 Cooling fan relay 2 circuit open or short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2



fan relay 2 through a scanning instrument. Does

the relay perform every instruction of “Connect” and

“Disconnect”?

-

Go to

"Diagnostic

aids"

Go to Step 3

3







4

1. Connect a test lamp between relay control circuit ans






5




terminal plug pin.



6 Replace the relay.



8

1. Clear DTC.





trouble code?



6.4C.4.60 DTC P0694 Cooling fan relay 2 circuit short to power

Circuit description

The 4 pins connected to the cooling fan relay 2 (controlling the AC condenser fan) are respectively the 12V power

supply terminal, main relay power supply, control terminal (ECU pin B_J3) and fan terminal.













Aids for diagnosis



Loosening terminal;


Broken keeper;









DTC P0694 Cooling fan relay 2 circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2



fan relay 2 through a scanning instrument. Does the

relay perform every instruction of “Connect” and

“Disconnect”?

-

Go to

"Diagnostic

aids"

Go to Step 3

3







4







5




terminal plug pin.



6 Replace the relay. Is replacement finished? - Go to Step 8 -


8

1. Clear DTC.





trouble code?



6.4C.4.61 DTC P0500 Inappropriate vehicle speed sensor signal

Circuit description

Vehicle speed sensor is an electromagnetic sensor. ECU pin B_D1 is vehicle speed sensor terminal. ECU will convert

frequency signal produced by vehicle speed sensor to vehicle speed signal. If engine is under a certain load and at a

certain speed and vehicle speed is low, DTC P0500 will be configured.


Engine coolant temperature＞0℃

Engine speed＞2000rpm

Air inflow of intake manifold ＞202mg/str









DTC P0500 Inappropriate vehicle speed sensor signal




Go to "Check of

powertrain

on-board

diagnostic

system"

2.




3. Monitor trouble code information with the

instrument. Is it the current trouble code if the

instrument indicates DTC P0500?

- Go to Step 3

Go to

"Diagnostic

aids"

3.


2. Disconnect the vehicle speed sensor.

3. Turn on the ignition switch without starting the

engine.

4. Check supply circuit of vehicle speed sensor with a

test lamp. Is the test lamp lit?


4. Check bonding circuit of vehicle speed sensor with a test

lamp. Is the test lamp lit? - Go to Step 6 Go to Step 5

5.

Check whether vehicle speed sensor wiring harness is

short to power and bonding, or open circuit, or whether

resistance is too high. Check for poor connection

between vehicle speed sensor terminal and ECU

terminal plug pin. Is failure detected and resolved?


6.

1. Remove the vehicle speed sensor and connect the

wiring harness plug.

2. Test voltage between VSS wiring harness plug 1 pin

and the earth with a multimeter.

3. When VSS is close to iron, the voltage should be 0V,

and when it’s away from iron, the voltage should be

12V. Is the detected value in line with this?


7. Check whether VSS signal wheel is damaged or

unproperly installed. Is failure detected and resolved? - Go to Step 8 Go to Step 9

8. Replace or reinstall the signal wheel. Is replacement

finished? - Go to Step 11 -

9. Replace the VSS. Is replacement finished? - Go to Step 11 -

10. Replace ECU. Is replacement finished? - Go to Step 11 -

11.




Is trouble code reset?



6.4C.4.62 DTC P0537 Air conditioning evaporator temperature sensor short to earth

Circuit description

There are two pins connected to the air conditioning evaporator temperature sensor, namely, sensor signal terminal

(ECU pin B_G1) and sensor ground (ECU pin A_E3).

The drive chip of the air conditioning evaporator temperature sensor can realize self diagnosis of driver stage through

comparing switching signal from CPU and actual potential of driver stage output terminal and can also send the fault

information to fault diagnostic module inside the CPU.


1.Engine coolant temperature is higher than 0℃.

2. Voltage of air conditioning compressor temperature sensor is less than 0.75V







‘

Aids for diagnosis


ECU poor connection - Check wiring harness connectors.

Incorrect arrangement of wiring harness - check if wiring harness is damaged.


DTC P0537 Air conditioning evaporator temperature sensor short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Turn OFF the ignition switch.

2. Disconnect the A/C evaporative temperature sensor.

Turn the ignition to ON without starting the engine.

3. Probe the power supply end of the A/C evaporative

temperature sensor with a test lamp that is

connected to a good ground. Is the test lamp ON?


3.

Test whether the voltage between the AC evaporative

temperature signal wire and the supply terminal is at low

level.


4 Replace the A/C evaporative temperature sensor.


5 Replace the ECU.


6

1. Clear the DTC.



with a malfunction diagnosis instrument.


trouble code?



6.4C.4.63 DTC P0538 Air conditioning evaporator temperature sensor circuit short to power

or open

Circuit description

There are two pins connected to the air conditioning evaporator temperature sensor, namely, sensor signal terminal

(ECU pin B_G1) and sensor ground (ECU pin A_E3).

The drive chip of the air conditioning evaporator temperature sensor can realize self diagnosis of driver stage through




● 1. Engine coolant temperature is more than 0℃

● 2. Voltage of air conditioning compressor temperature sensor is more than 4.87V


● It will enter into failure memory immediately a malfunction arises.

● Malfunction indicating lamp will not be lit.



● Trouble code can be cleared with a malfunction diagnosis instrument.

Aids for diagnosis


● ECU poor connection - Check wiring harness connectors.

● Incorrect arrangement of wiring harness - check if wiring harness is damaged.


DTC P0538 Air conditioning evaporator temperature sensor circuit short to power or open




Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Turn OFF the ignition switch.

2. Disconnect the A/C evaporative temperature sensor.

Turn the ignition to ON without starting the engine.

3. Probe the power supply end of the A/C evaporative

temperature sensor with a test lamp that is

connected to a good ground. Is the test lamp ON?


3.

Test whether the voltage between the AC evaporative

temperature signal wire and the supply terminal is at low

level.


4 Replace the A/C evaporative temperature sensor.


5 Replace the ECU.


6

1. Clear the DTC.





trouble code?



6.4C.4.64 DTC P0645 A/C compressor relay circuit open

Description:

The four pins connected with the A/C compressor relay respectively are the 12V constant power supply terminal, 12V

main relay power supply, control signal terminal (connecting ECU pin B_N2) and A/C compressor electromagnetic

clutch supply terminal.

A/C compressor relay is driven by a drive chip which can realize self diagnosis of the internal circuit through comparing

switching signal from CPU and actual potential of ECU output terminal and can also send the fault information to fault

diagnostic module inside the CPU.


An open circuit is found in the module’s internal circuit.







Aids for diagnosis



1. Poor connection of ECU or fuel pump relay - Check the wiring harness connectors:

Loosening terminal;


Broken locking plate;



2. Wire harness is damaged – check if the wire harness is damaged. See the vehicle mileage in the recorded data of

faultafter the last diagnosis failure to determine the occurrence frequency of self-diagnosis trouble code, which

helps to diagnose such situation.


DTC P0645 A/C compressor relay circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2.





If DTCP0645 is displayed on malfunction diagnosis

instrument, is this ignition a failure?

- Go to Step 3

Go to

"Diagnostic

aids"

3.





lamp.



4.

1. Connect a test lamp between relay control circuit

ans the supply terminal.

2. Instruct the connection and disconnection of the

relay with the malfunction diagnosis instrument. Can

every instruction turn on or off the test lamp?


5. Check whether relay control circuit is short to earth. Is

failure detected and resolved? - Go to Step 9 Go to Step 6

6.

Check whether relay circuit is short to earth, whether

there is a high resistance in the wiring harness and

whether there is poor connection between ECU terminal

and relay terminal plug pin. Is failure detected and

resolved?


7. Replace the relay. Is replacement finished? - Go to Step 9 -

8. Replace ECU. Is replacement finished? - Go to Step 9 -

9.

1. Clear DTC.





DTC P0645?



6.4C.4.65 DTC P0646 A/C compressor relay circuit short to earth

Description:








A circuit short to earth is found in the module’s internal circuit.







Aids for diagnosis

Intermittent faults may be caused by poor connection, wornout insulant or broken wire inside the covered cable.


3. Poor connection of ECU or fuel pump relay- Check the wiring harness connectors:

Loosening terminal;





4. Wire harness is damaged – check if the wire harness is damaged. See the vehicle mileage in the recorded data of

fault after the last diagnosis failure to determine the occurrence frequency of self-diagnosis trouble code, which

helps to diagnose such situation.


DTC P0646 A/C compressor relay circuit short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2.



the DTC.


information.

Does the scan tool indicate the DTCP0646 failed this

ignition?

- Go to Step 3

Go to

"Diagnostic

aids"

3.


2. Disconnect the relay. Turn the ignition to ON without

starting the engine.

3. Probe the power supply end of the relay with a test

lamp that is connected to a good ground.

Is the test lamp ON?


4.

1. Connect a test lamp between the control circuit of

relay and the power supply end of relay.

2. Using a scan tool, command the relay ON then OFF.

Does the test lamp turn ON and OFF with each

command?


5. Check the control circuit of relay for a short to ground.

Did you find and repair the condition? - Go to Step 9 Go to Step 6

6.

Check for a short to ground in relay circuit, for the high

resistance in wiring harness and for poor contact of pins

at ECU end or relay end.

Did you find and repair the condition?


7. Replace the relay.


8. Replace the ECU.


9.

1. Clear the DTC.


the DTC. Use the scan tool to monitor the trouble

information.

Does the scan tool indicate that the DTCP0646 is

current?



6.4C.4.66 DTC P0647 A/C compressor relay circuit short to power

Description:















Aids for diagnosis

Intermittent faults may be caused by poor connection, wornout insulant or broken wire inside the covered cable.


Poor connection of ECU or fuel pump relay - Check the wiring harness connectors:

Loosening terminal;





Wire harness is damaged – check if the wire harness is damaged. See the vehicle mileage in the recorded data of fault

after the last diagnosis failure to determine the occurrence frequency of self-diagnosis trouble code, which helps to

diagnose such situation.


DTC P0647 A/C compressor relay circuit short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2.



the DTC.


information.

Does the scan tool indicate the DTCP0647 failed this

ignition?

- Go to Step 3

Go to

"Diagnostic

aids"

3.


2. Disconnect the relay. Turn the ignition to ON without

starting the engine.

3. Probe the power supply end of the relay with a test

lamp that is connected to a good ground.

Is the test lamp ON?


4.

1. Connect a test lamp between the control circuit of

relay and the power supply end of relay.

2. Using a scan tool, command the relay ON then OFF.

Does the test lamp turn ON and OFF with each

command?


5. Check the control circuit of relay for a short to power

supply. Did you find and repair the condition? - Go to Step 9 Go to Step 6

6.

Check for an open in relay circuit, for the high resistance

in wiring harness and for poor contact of pins at ECU end

or relay end.



7. Replace the relay.


8. Replace the ECU.


9.

1. Clear the DTC.


the DTC. Use the scan tool to monitor the trouble

information.

Does the scan tool indicate that the DTCP0647 is

current?



6.4C.4.67 DTC P0685 Main relay circuit break to earth

Description:

The four pins connected with the main relay respectively are the 12V constant power supply terminal (relay terminal pin

30), 12V constant power supply terminal (relay terminal pin 85), control signal terminal (relay terminal pin 86, connecting

ECU pin B_K3) and main relay power output terminal (relay terminal pin 87).

The main relay is driven by a drive chip which can realize self diagnosis of the internal circuit through comparing




An open circuit is found in the module’s internal circuit.







Aids for diagnosis


Damaged wiring harness - check if wiring harness is damaged.

If the wiring harness looks normal, observe the system voltage shown on the malfunction diagnosis instrument while

moving related connectors and wires of the ECU, instrument wiring harness and engine wiring harness. If the display

shows difference, it indicates defects in this section.

If the DTC cannot be reproduced, refer to vehicle driving distance since the last failed diagnosis test in the “failure

records”. It will be of help in determining the occurrence frequency of faults resulting in the configuration of this DTC.

This is helpful to the diagnosis of this situation.


DTC P0685 Main relay circuit open


1.

Did you perform the check of powertrain on-board

diagnostic (OBD) system?

Is system check completed?

- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2.

1. Disconnect the main relay.

2. Measure the resistance between main relay 85 and

86 to see whether it’s within the specified range.

70-110Ω Go to Step 3 Go to Step 6

3.

1. Set ignition switch to “ON”.

2. Test the ignition supply circuit of relay 85 terminal

with a reliably grounded test lamp. Is the test lamp

lit?

- Go to Step 4

Go to

"Diagnostic

aids"

4.

Set ignition switch to “ON”.

Disconnect the ECM wiring harness.

Test the ignition supply circuit of relay 1 terminal with a

reliably grounded test lamp.



5.

Repair the high voltage from ECM connector terminal

B_K3 to relay 85 terminal.

Is the reparation completed?

- Go to Step 7 -

6. Replace the relay. Is the replacement completed? - Go to Step 7 -

7.



temperature.


operating conditions.

Monitor the DTC with the diagnosis instrument. Is DTC

reset?


8. Check all newly set DTCs.

Are all DTCs displayed diagnosed? -

Back to DTC

application

system desktop

System OK


6.4C.4.68 DTC P0686 Main relay circuit short to earth

Description:















Aids for diagnosis


Poorly connected or damaged wiring harness - check if wiring harness is damaged. If the wiring harness looks normal,

observe the system voltage shown on the malfunction diagnosis instrument while moving related connectors and wires

of the ECU, instrument wiring harness and engine wiring harness. If the display shows difference, it indicates defects in

this section.





DTC P0686 Main relay circuit short to earth


1.




- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2.





3.


2. Test the ignition supply circuit of relay 85 terminal

with a reliably grounded test lamp. Is the test lamp

lit?

- Go to Step 4

Go to

"Diagnostic

aids"

4.







5.




- Go to Step 7 -


7.



temperature.



Monitor the DTC with the diagnosis instrument. Is DTC

reset?




Back to DTC

application

system desktop

System OK


6.4C.4.69 DTC P0687 Main relay circuit short to power

Description:















Aids for diagnosis


Poorly connected or damaged wiring harness - check if wiring harness is damaged.

If the wiring harness looks normal, observe the system voltage shown on the malfunction diagnosis instrument while

moving related connectors and wires of the ECU, instrument wiring harness and engine wiring harness. If the display

shows difference, it indicates defects in this section.





DTC P0687 Main relay circuit short to power


1.




- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2.





3.


2. Test the ignition supply circuit of relay 1 terminal with

a reliably grounded test lamp.


- Go to Step 4

Go to

"Diagnostic

aids"

4.







5.




- Go to Step 7

-


7.



temperature.



4. Monitor the DTC with the diagnosis instrument.

Is DTC reset?




Back to DTC

application

system desktop

System OK


6.4 C. 4.70 DTC P2413 EGR valve position self-learning error Circuit description After starting the ignition key, tell the learning conditions of EGR valve null feedback voltage; after getting the learning conditions, conduct the self-learning of null feedback voltage from the compressed and stretched direction of EGR valve return spring, and get the initial position of EGR valve by null feedback voltage.(EGR valve is usually in a normally closed state, and open when the engine is in the medium load) Conditions for setting trouble code

1. 0.28 V < EGR reach the sensor voltage < 1.75 V under the low position 2. EGR valve is closed.







Diagnosis and maintenance: 1 Open the ignition switch, use the diagnostic instrument to test whether EGR position sensor parameter is between

0% and 4% or not. 2. Whether there is vacuum leak between EGR valve and intake manifold. 3. Whether there is carbon compounds and ash clogging in the exhaust manifold and EGR valve. 4. Whether there is leakage and clogging in the pressure sensor of intake manifold. 5. Check if the voltage between EGR valve pines AC_4 (Blue/brown) and B_H2 (brown) is 5 v, and on and off of ZK14

(red) and B_O2 lines, the signal voltage between A_E1 and B_H2 (brown) is between 0.3 and 3 v. 6. Whether EGR valve has any parts damaged.


6.4 C. 4.71 DTC P0488 EGR valve position control error Circuit description After starting the ignition key, tell the learning conditions of EGR valve null feedback voltage; after getting the learning conditions, conduct the self-learning of null feedback voltage from the compressed and stretched direction of EGR valve return spring, and get the initial position of EGR valve by null feedback voltage.(EGR valve is usually in a normally closed state, and open when the engine is in the medium load)


1. Absolute value EGR valve I control >45%




Prohibit EGR valve moving/EGR self-learning




Diagnosis and maintenance: 1. Open the ignition switch, use the diagnostic instrument to test whether EGR position sensor parameter is between

0% and 4% or not. 2. Whether there is vacuum leak between EGR valve and intake manifold. 3. Whether there is carbon compounds and ash clogging in the exhaust manifold and EGR valve. 4. Whether there is leakage and clogging in the pressure sensor of intake manifold. 5. Check if the voltage between AC_4 (Blue and brown) and B_H2 (brown) of EGR valve pin is 5 v, on and off of pin of

control valve ZK14 (red) and B_O2 line, the signal voltage between A_E1 and B_H2 (brown) is between 0.3 to 3 v. 6. Whether EGR valve has any parts damaged.


6.4 C. 4.72 DTC P0488 ETC electrical failure open circuit Circuit description Throttle actuator control system uses two throttle position sensors to monitor the throttle. Throttle position sensor 1 and 2 are located inside the throttle body assembly.The sensor has the following circuit: One 5 v reference voltage One low-level reference voltage circuit Two signal circuits At the same time, use two processors to monitor data of actuator control system of throttle body. Two processors are located inside the engine control module. Each signal circuit provides the signal voltage which is in direct proportion to throttle displacement for two processors. Two processors will monitor the mutual data to confirm the correct calculation of throttle position. Signals of sensor 1 and 2 are complementary, and the sum of their voltage value is 5 v. Sensor 1 is negative correlation signal, and sensor 2 is positively correlation signal.

Conditions for setting trouble code Detect ETC electrical failure open circuit The circuit needs overheating protection. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.

Malfunction indicating lamp will not be lit. Prohibit oxygen sensor diagnosis, air-fuel ratio conttol and MAP diagnosis Conditions for turning off the MIL/clearing DTC


If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.. Diagnosis and maintenance 1 Place ignition switch being ON, observe the voltage parameters of “throttle position sensor” of fault diagnosis tester.

Reading shall be between 0.25 and 4.59 V, and changes with the input of accelerator pedal. 2 Place ignition switch being ON, observe the voltage parameters of “throttle position sensor” of fault diagnosis tester.

Reading shall be between 4.75 and 0.35 V, and changes with the input of accelerator pedal. 3 Place ignition switch being ON, use multimeter to test whether the voltage between 5 V reference voltage circuit end

(Red and white) and bonding is between 4.8 V and 5.2 V. 4 Use multimeter to test whether the circuit between throttle position sensor 1 connector pin (white and yellow) and

ECU pin A_F3 is conducted, and the circuit between throttle position sensor 2 connectors (brown and white) and ECU pin A_C1 is conducted, if not, replace the circuit.

5 Check whether the electronic throttle is blocked or damaged, if so, replace the throttle body. 6 Replace the ECU, remove trouble codes, read the trouble code after repeated driving cycle, and detect if trouble

code appears again.


6.4 C. 4.73 DTC P0638 ETC_1 unreasonable output signal of position controller Circuit description Throttle actuator control system uses two throttle position sensors to monitor the throttle. Throttle position sensor 1 and 2 are located inside the throttle body assembly. The sensor has the following circuit: One 5 v reference voltage One low-level reference voltage circuit Two signal circuits At the same time, use two processors to monitor data of actuator control system of throttle body. Two processors are located inside the engine control module. Each signal circuit provides the signal voltage which is in direct proportion to throttle displacement for two processors. Two processors will monitor the mutual data to confirm the correct calculation of throttle position. Signals of sensor 1 and 2 are complementary, and the sum of their voltage value is 5 v. Sensor 1 is negative correlation signal, and sensor 2 is positively correlation signal.

Conditions for setting trouble code 1. Throttle PMW>90% 2. Battery voltage>8V Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.

Malfunction indicating lamp will not be lit. Prohibit oxygen sensor diagnosis, air-fuel ratio control and MAP diagnosis Conditions for turning off the MIL/clearing DTC



Diagnosis and maintenance 1 Place ignition switch being ON, observe the voltage parameters of “throttle position sensor” of fault diagnosis tester.

Reading shall be between 0.25 and 4.59 V, and changes with the input of accelerator pedal. 2 Place ignition switch being ON, observe the voltage parameters of “throttle position sensor” of fault diagnosis tester.

Reading shall be between 4.75 and 0.35 V, and changes with the input of accelerator pedal. 3 Place ignition switch being ON, use multimeter to test whether the voltage between 5 V reference voltage circuit end

(Red and white) and bonding is between 4.8 V and 5.2 V. 4 Use a multimeter to test whether the circuit between throttle position sensor 1 connector pin (white and yellow) and



code appears again.


6.4C.4.74 DTC P0638 Unreasonable output signal of ETC_2 position controller Circuit description Throttle actuator control system uses two throttle position sensors to monitor the throttle. Throttle position sensor 1 and 2 are located inside the throttle body assembly. The sensor has the following circuit: One 5 v reference voltage One low-level reference voltage circuit Two signal circuits At the same time, use two processors to monitor data of actuator control system of throttle body. Two processors are located inside the engine control module. Each signal circuit provides the signal voltage which is in direct proportion to throttle displacement for two processors. Two processors will monitor the mutual data to confirm the correct calculation of throttle position. Signals of sensor 1 and 2 are complementary, and the sum of their voltage value is 5 v. Sensor 1 is negative correlation signal, and sensor 2 is positively correlation signal.

Conditions for setting trouble code 1. Throttle PMW>90% Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises. Malfunction indicating lamp will not be lit. Prohibit oxygen sensor diagnosis, air-fuel ratio control and MAP diagnosis Conditions for turning off the MIL/clearing DTC When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared.


Diagnosis and maintenance 1 Place ignition switch being ON, observe the voltage parameters of “throttle position sensor 1” of fault diagnosis tester.

Reading shall be between 0.25 and 4.59 V, and changes with the input of accelerator pedal. 2 Place ignition switch being ON, observe the voltage parameters of “throttle position sensor 2” of fault diagnosis tester.

Reading shall be between 4.75 and 0.35 V, and changes with the input of accelerator pedal. 3 Place ignition switch being ON, use a multimeter to test whether the voltage between 5 V reference voltage circuit

end (Red and white) and bonding is between 4.8 V and 5.2 V. 4 Use a multimeter to test whether the circuit between throttle position sensor 1 connector pin (white and yellow) and



code appears again.


6.4C.4.75 P060A Monitoring fault Circuit description During the engine operation, ECU constantly conducts the monitoring of the following parameters, and if finding that the parameter is beyond the range value under the operating condition, set the fault. Monitoring of torque demand – check the intake air pressure sensor and circuit. Monitoring of torque loss – check water temperature sensor and circuit Monitoring of abnormal signal of engine speed – check crankshaft and camshaft position sensors and circuit Monitoring of dual signal of electronic accelerator pedal – check accelerator pedal sensor and circuit Monitoring of dual signal of electronic throttle valve - check electronic throttle valve and circuit Conditions for setting trouble code The above parameters detected by ECT are not in the normal range. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises. Malfunction indicating lamp (MIL) will not be lit. Prohibit oxygen sensor diagnosis, air-fuel ratio control and MAP diagnosis Conditions for turning off the MIL/clearing DTC When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared.

If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL. Diagnosis and maintenance: 1 Use a multimeter to check if the output voltage between output end of air intake pressure sensor (brown and red) and

the grounding end is 5 V, if not, there is short circuit and open circuit inside the sensor, and use the diagnostic instrument to detect if the sensor signal voltage is within the prescribed scope (0.5-4.5 V), if not, replace the air intake pressure sensor.

2 Use a multimeter to check if the the output voltage between output end (white and purple) of engine temperature sensor and the grounding end is 5 v, and use a multimeter to check if the internal resistance of engine temperature sensor is near 2KΩ—4KΩ (room temperature), if not, replace the water temperature sensor.

3 Use a multimeter to check if the output voltage between output end and the grounding end of crankshaft and camshaft position sensor is 5 V.

4 Check if the circuit of accelerator pedal position sensor is on or off, if there is short circuit and open circuit, if dual signal voltage is within the prescribed scope, by a factor of two.

5. Use a multimeter to check if the output voltage between output end (Blue and yellow) and the grounding end of throttle position sensor is 5 V, if not, check there is short circuit and open circuit, and replace the circuit. Use a multimeter to check if the circuit between throttle position sensor 1/ throttle position sensor 2 and ECU pin is conducted, if not, replace the circuit.

6 Replace the ECU, clear trouble codes, read the trouble code after repeated driving cycle, and detect if trouble code appears again.


6.4C.4.76 DTC P0016 Intake Camshaft Position Offset Circuit Description Camshaft position sensor is also known as cylinder sensor. It is installed in the front or rear part of the camshaft or inside the distributor. And its role is to collect the position signal of the camshaft and input it into the control unit ECU, so that the control unit ECU can identify the top dead point of the compression of the first cylinder. And then the sequential fuel infection control, ignition timing control and knock selection control can be performed. The camshaft position signal can also identify the first ignition timing for the engine start. This trouble code is that the actual camshaft position is inconsistent with the set camshaft position and the fault point is that the camshaft is not to the set position or the camshaft position sensor has wrong feedback. Conditions for setting trouble code 1. The difference between the self-learning position and the theoretical position on the edge of the camshaft shall be larger than 24. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises. Malfunction indicating lamp (MIL) will not be lit. It is forbidden to carry out oxygen sensor diagnosis, air-fuel ratio control and MAP diagnosis Conditions for turning off the MIL/clearing DTC When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared. If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL. Diagnosis and Maintenance: 1 Inspect if the voltage between the signal end (blue-black) and the grounding end of the camshaft position sensor with

the multimeter is within the range of 4.75v-5.25v，and if the output voltage of the voltage output end and the

grounding end is 5V. And if not, inspect if the conductor between the pin(blue-black) corresponding to the sensor signal and ECU pin (B_C3) is conducted with the multimeter, and if not, replace the line.

2 Check if the camshaft has damage or blockage and if the mounting position has deviation. 3 Check if the intake VVT control valve has catching phenomenon, which will cause camshaft position offset. 4 Check if the engine control module receiving signals are normal.


6.4C.4.77 DTC P2176 TPS cannot reach cutoff point/ TPS position self-leaning fault Circuit Description The throttle position sensor is mounted on the throttle. It can convert the throttle opening angle into voltage signal and send it to ECU, so that the amount of fuel injection can be controlled at different opening states of the throttle. Throttle position senor 1 and 2 are located inside the throttle body assembly. The sensor has the following circuits: A 5V reference voltage A low level reference voltage circuit Two signal circuits

Conditions for setting trouble code Detect the signal of the throttle position sensor inside the ECU automatically. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises. Malfunction indicating lamp (MIL) will not be lit. It is forbidden to carry out oxygen sensor diagnosis, air-fuel ratio control and MAP diagnosis Conditions for turning off the MIL/clearing DTC When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared. If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL. Diagnosis and Maintenance: 1 Check if the throttle has damage or blockage . 2 Inspect if the voltage between the power output end (red-white line) and the grounding end of the throttle position

sensor with the multimeter is 5v. And then start the engine and depress the accelerator and measure if the voltage of Signal 1 of the throttle position sensor changes between 0.25V and 4.75V with a diagnostic unit and if the Signal 2 of the throttle position sensor is variable between 4.75V and 0.25V. And if not, replace the throttle assembly.

3 Check if the conductor between the pin (white-yellow) corresponding to the signal end of the throttle position sensor 1 and ECU pin (A_F3) and the conductor between the pin (brown-white) corresponding to the signal end of the throttle position sensor 2 and ECU pin (A_C1) are conducted; and if not, replace the line.

4 Replace ECU and clear trouble code. And then check if the trouble code reappears again after several driving cycles.


6.4C.4.78 DTC P0121 Unreasonable throttle position sensor 1 signal and DTC P0221 unreasonable throttle position sensor 2 signal Circuit Description The throttle position sensor is mounted on the throttle. It can convert the throttle opening angle into voltage signal and send it to ECU, so that the amount of fuel injection can be controlled at different opening states of the throttle. The throttle position sensor has two signal voltages, which form complement voltage Conditions for setting trouble code Control the difference of the air flow is greater than the minimum limit through controlling the air flow in the intake manifold based on the throttle position sensor TPS-1. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises. Malfunction indicating lamp (MIL) will not be lit. The engine is in idle state. The conditions to clear trouble indicator light/to diagnose the trouble code The trouble code can be cleared after 40 consecutive warm-up cycles without fault If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL. Diagnosis and Maintenance: 1 Check if the voltage value between the throttle position sensor 5V reference voltage (red-white) and the grounding is

5V with the multimeter and measure if the total voltage of the voltage of the throttle position sensor and the signal voltage of the throttle position sensor 2 is 5V with the diagnostic unit; and if not, replace the throttle body assembly.

2 Check if the throttle has damage or blockage, which leads to the deviation between the theoretical air flow and actual air flow.

3 Check if the intake manifold has blockage. 4 Check if the conductor between the pin (white-yellow) corresponding to the signal end of the throttle position sensor

1 and ECU pin (A_F3) and the conductor between the pin (brown-white) corresponding to the signal end of the throttle position sensor 2 and ECU pin (A_C1) are conducted; so as to judge if ECU signal receiving and feedback are normal; and if not, replace the circuit.

5 Replace ECU and clear trouble code. And then check if the trouble code reappears again after several driving cycles.


6.4C.4.79 DTC P0650 Malfunction indicating lamp circuit open, short to earth or short to power

Circult Description:

The two pins connected to the malfunction indicating lamp (MIL) are the ignition switch signal input terminal (MIL

terminal pin connecting main relay 87) and control signal terminal (another MIL terminal pin connecting ECU pin B_H4).

The MIL is driven by a drive chip which can realize self diagnosis of the internal circuit through comparing switching

signal from CPU and actual potential of ECU output terminal and can also send the fault information to fault diagnostic


The fault types that can be diagnosed:

The biggest fault: the pins are short to power when the internal control driver stage is connected.

The smallest fault: the pins are short to earth when the internal control driver stage is disconnected.

Signal fault: the pins are open or broken when the internal control driver stage is disconnected.

Trouble code of all the above three faults is DTC P0650.


Line fault is found in the ECM internal circuit.







Aids for diagnosis



Loosening terminal;


Broken keeper;



2. Use a matching terminal to get the correct terminal tension.

3. Wiring harness damaged or not-check if wiring harness is damaged. If the instrument shows no problem,

disconnect the ECU and connect the ignition switch. While moving connectors and wiring harness related with the

MIL, observe the voltage change of the digital multimeter connected between MLI control circuit on the ECM wiring

harness connector and the earth. If the voltage shows difference, it indicates defects in this section.


determining the occurrence frequency of faults resulting in the configuration of this DTC. This is helpful to the diagnosis

of this situation.


DTC P0650 Malfunction indicating lamp circuit open, short to earth or short to power

Step Action Yes No

1. Did you perform the check of powertrain on-board diagnostic (OBD)

system? Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2. Are there any additional DTCs? Go to Step 3 Go to "Diagnostic

aids"

3. Turn the ignition ON and observe the instrument.

Is the MIL ON? Go to Step 4 Go to Step 5


Is the MIL OFF?

Go to

"Diagnostic

aids"

Go to Step 6

5.


2. Remove the instrument panel.

3. Check the MIL.

Was the MIL damaged and replaced?


6.

1. Connect an unpowered test lamp in series between the MIL control

circuit and the battery.


3. Use a scan too to operate the MIL.

Does the test lamp turn ON and OFF with each command?


7. Check the instrument connector for poor connection.

Did you find and repair the condition? Go to Step 11 Go to Step 9

8.

Check for a short to power supply, a short to ground and an open in the

MIL circuit, for the poor contact of pins at ECU end or MIL end and for

the high resistance in the wring harness.



9. Replace the instrument panel.


10. Replace the ECU.


11.

1. Clear the DTC.

2. Operate the vehicle within the conditions for running the DTC. Use

the scan tool to monitor the trouble information.

Does the scan tool indicate the DTCP0650 is current?



6.4C.4.80 DTC P0562 Low power supply voltage

Description:

Nominal voltage of the system is 12V. However, actual voltage value under normal circumstances will vary between

8-16V. ECU will take samples of system voltage after it goes through the main relay and monitor and diagnose on the

basis of the sampled values. If system voltage is below the threshold value of 8V, DTC P0562 will be configured.


Ignition switch is in the state of ON;

Voltage is under 8V.







Aids for diagnosis



observe the system voltage shown on the scanning instrument while moving related connectors and wires of the ECU,

instrument wiring harness and engine wiring harness. If the display shows difference, it indicates defects in this section.





DTC P0562 Low power supply voltage




Go to "Check of

powertrain

on-board

diagnostic

system"

2


the DTC.



information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

1. Start the engine and allow the rotational speed to be

greater than 1000 RPM.

2. Use a multi-meter to test the engine charging

voltage.

Is the voltage within the value specified?

8-16V Go to Step 9 Go to Step 4

4. Is the charging voltage within the specified value at the

different engine speeds? 8-16V Go to Step 6 Go to Step 5

5

Check the charging wiring harness from the engine to the

battery for break circuit, short circuit, over-high internal

resistance of the wiring harness or poor connection of

engine wiring harness plug pin. Is any failure detected

and repaired?


6

Check the circuit between the battery and ECU wiring

harness terminal B_P3 pin for break circuit, short circuit,

over-high internal resistance of the wiring harness or

poor connection of ECU terminal pin. Is any failure

detected and repaired?


7. Replace the generator.

Did you correct the condition? - Go to Step 9 Go to Step 8

8. Replace the ECU.


9

1. Use a scan tool in order to clear the DTC.

2. Start and run the engine.


information.

Is the DTC reset?



6.4C.4.81 DTC P0563 High power supply voltage

Description:

Nominal voltage of the system is 12V. However, actual voltage value under normal circumstances will vary between

8~16V. ECU will take samples of system voltage after it goes through the main relay and monitor and diagnose on the

basis of the sampled values. If system voltage is higher than the threshold value of 16V, DTC P0563 will be configured.



Voltage is above 16V.







Aids for diagnosis



observe the system voltage shown on the scanning instrument while moving related connectors and wires of the ECU,

instrument wiring harness and engine wiring harness. If the display shows difference, it indicates defects in this section.





DTC P0563 High power supply voltage




Go to "Check of

powertrain

on-board

diagnostic

system"

2

1. Operate the vehicle within the failure generation

conditions.



information.


current?

- Go to Step 3

Go to

"Diagnostic

aids"

3.

1. Start the engine and allow the rotational speed to be

greater than 1000 RPM.

2. Observe the system voltage on the scan tool.

Is the system voltage within the value specified?

8-16V Go to Step 9 Go to Step 4

4. Is the charging voltage within the specified value at the

different engine speeds? 8-16V Go to Step 6 Go to Step 5

5

Check the charging wiring harness from the engine to the

battery for break circuit, short circuit, over-high internal

resistance of the wiring harness or poor connection of

engine wiring harness plug pin. Is any failure detected

and repaired?


6

Check the circuit between the battery and ECU wiring

harness terminal B_P3 pin for break circuit, short circuit,

over-high internal resistance of the wiring harness or

poor connection of ECU terminal pin. Is any failure

detected and repaired?


7. Replace the generator.

Did you correct the condition? - Go to Step 9 Go to Step 8

8. Replace the ECU.


9

1. Use a scan tool in order to clear the DTC.

2. Start and run the engine.


information.

Is the DTC reset?



6.4C.4.82 DTC P0171 Fuel system diagnosis - too lean

Description:

ECM controls the air/fuel measuring system to provide the optimal possible combination of dynamic performance, fuel

economy and emission control. Methods in controlling fuel supply are different for closed loops and open loops. For

open loops, ECM determines fuel supply on the basis of each sensor signal without the input of the heated oxygen

sensor (HO2S).For closed loops, ECM will combine the heated oxygen sensor input value and the purging signal value

in determining short-term and long-term fuel regulation values. If the heated oxygen sensor shows it’s too lean, fuel

regulation value should be above 0%. If the heated oxygen sensor shows it’s too rich, fuel regulation value should be

below 0%. The short-term fuel regulation value will change quickly to respond to the voltage signal changes of the

heated oxygen sensor. Long-term fuel regulation will make rough adjustments to maintain the air-fuel ration at 14.7:1. A

unit group consists of the combined information of the engine speed and engine load, covering fully the performance of

the vehicle. Diagnosis of the long-term fuel regulation is based on the average value of the currently used unit. ECM

chooses the unit needed on the basis of engine speed and engine load.Fuel regulation diagnosis will check whether the

fault of too rich does exist or whether the “too rich” problem is caused by the over-redundancy of vapor from the

evaporation emission (EVAP) canister.

If “too lean” fault is detected by the ECM, DTC P0171 will be configured. If “too rich” fault is detected by the ECM, DTC

P0172 will be configured.


Ignition switch is “ON”.

Water temperature is greater than 65℃

Intake air temperature is higher than -7.5℃

Intake air amount is more than 71mg/str

Ambient temperature is greater than -7.5℃

Up to closed-loop control









DTC P0171 Fuel system diagnosis-too lean




Go to "Check of

powertrain

on-board diagnostic

system"

2 Is any other DTC set apart from P0171? -

Go to

"Malfunction

Diagnosis List".

Go to Step 3

3


2. Let the engine get to operating temperature and

enter into closed loop model.

3. Observe “Long-term fuel regulation” value with a

diagnosis instrument to see whether it’s greater than

the specified value.

30% Go to Step 4 Go to "Diagnostic

aids"

4


2. Set to “NEUTRAL” position.

3. Close all accessories.

4. Let the engine idle.

5. Observe the intake manifold pressure with a

diagnosis instrument to see whether it’s within the

specified range.

20-60Kpa Go to Step 5

Check intake

manifold pressure

sensor.

5

1. Connect an injector test lamp between the injector

control circuit and the ignition voltage circuit.

2. Start the engine. Does the test lamp blink?


6

1. Shut the engine.

2. Check for the following situations:

● Vacuum hose cracks, twists or misconnections;

● Jammed inlet pipes;

● Throttle blocked by foreign matters;

Are failures detected and resolved?


7

1. Shut the engine.


1. Is the heated oxygen sensor correctly installed?

2. Is there any electrical fault of the heated oxygen

sensor?

Are the above failures detected and resolved?

- Go to Step 9 Go to mechanical

parts of the engine

8.

1. Shut the engine.


● Too much fuel in the crankcase;

● The evaporation system not functioning properly;

● The fuel system not functioning properly;


- Go to Step 9 Go to diagnosis of

the fuel system

9


instrument.

2. Shut the engine for 30s.


4. Does malfunction diagnosis code fail to pass this

ignition loop test?


10 Is there any DTC that has not been diagnosed?

Go to

"Malfunction

Diagnosis List"

System OK


6.4C.4.83 DTC P0172 Fuel system diagnosis - too rich

Description:

ECM controls the air/fuel measuring system to provide the optimal possible combination of dynamic performance, fuel

economy and emission control. Methods in controlling fuel supply are different for closed loops and open loops. For

open loops, ECM determines fuel supply on the basis of each sensor signal without the input of the heated oxygen

sensor (HO2S). For closed loops, ECM will combine the heated oxygen sensor input value and the purging signal value

in determining short-term and long-term fuel regulation values. If the heated oxygen sensor shows it’s too lean, fuel

regulation value should be above 0%. If the heated oxygen sensor shows it’s too rich, fuel regulation value should be

below 0%. The short-term fuel regulation value will change quickly to respond to the voltage signal changes of the

heated oxygen sensor. Long-term fuel regulation will make rough adjustments to maintain the air-fuel ration at 14.7:1. A

unit group consists of the combined information of the engine speed and engine load, covering fully the performance of

the vehicle. Diagnosis of the long-term fuel regulation is based on the average value of the currently used unit. ECM

chooses the unit needed on the basis of engine speed and engine load. Fuel regulation diagnosis will check whether the

fault of too rich does exist or whether the “too rich” problem is caused by the over-redundancy of vapor from the

evaporation emission (EVAP) canister.

If “too lean” fault is detected by the ECM, DTC P0171 will be configured. If “too rich” fault is detected by the ECM, DTC

P0172 will be configured.



Water temperature is greater than 65℃

Intake air temperature is higher than -7.5℃

Intake air amount is more than 71mg/str

Ambient temperature is greater than -7.5℃

Up to closed-loop control



Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 1 continuous driving cycle..






DTC P0172 Fuel system diagnosis-too rich




Go to "Check of

powertrain

on-board

diagnostic

system"

2 Is any other DTC set apart from P0172? -

Go to

"Malfunction

Diagnosis List"

Go to Step 3

3


2. Let the engine get to operating temperature and

enter into closed loop model.

3. Observe “Long-term fuel regulation” value with a

diagnosis instrument to see whether it’s greater than

the specified value.

30% Go to Step 4

Go to

"Diagnostic

aids"

4


2. Set to “NEUTRAL” position.

3. Close all accessories.


5. Observe the intake manifold pressure with a

diagnosis instrument to see whether it’s within the

specified range.

24-60Kpa Go to Step 5

Check intake

manifold

pressure sensor

5

1. Connect an injector test lamp between the injector

control circuit and the ignition voltage circuit.

2. Start the engine. Does the test lamp blink?


6

1. Shut the engine.


Vacuum hose cracks, twists or misconnections;

Jammed inlet pipes;

Throttle blocked by foreign matters;



7

1. Shut the engine.


Is the heated oxygen sensor correctly installed?

Is there any electrical fault of the heated oxygen

sensor?


- Go to Step 9

Go to

mechanical

parts of the

engine

8.

1. Shut the engine.


Too much fuel in the crankcase;

The evaporation system not functioning properly;

The fuel system not functioning properly;

Are the above failures detected and resolved?

- Go to Step 9

Go to diagnosis

of the fuel

system

9


instrument.

2. Shut the engine for 30s.


4. Does malfunction diagnosis code fail to pass this

ignition loop test?


10 Is there any DTC that has not been diagnosed? Go to

“Malfunction System OK



Diagnosis List”

6.4C.4.84 DTC P0133 Slow conversion time response of upstream oxygen sensor

Circuit description

The 4 pins connected to the oxygen sensor (short as HO2S) respectively are 12V heater power terminal, sensor

terminal (ECU terminal pin B_F2), signal terminal (ECU terminal pin B_C1) and heater control terminal (ECU terminal

pin B_N4).


circuit. Oxygen sensor inputs oxygen sensor voltage through the ECU pin B_C1. The oxygen sensor signal voltage will




fuel injected according to the gas mixture concentration sent by the signal. When the temperature is below 400℃, the

oxygen sensor is equal to an open circuit and will not produce voltage. Open circuit or low temperature oxygen sensor

will lead to the “open-loop” operation.



Exhaust gas temperature at the front oxygen position is higher than 600℃

Intake air flow is between 15 and 400mg/str

Engine temperature is greater than 84.75℃

Engine speed is between 512 and 4608rpm.









DTC P0133 Slow conversion time response of upstream oxygen sensor


1

Perform “Diagnosis system check-engine control

system”.

Is system check finished?

Go to Step 2

Go to

“Diagnostic

system

check-Engine

Control system”

2


2. Let engine run until normal working temperature is

reached.

3. Check whether “Closed Loop” operation is in

operation.

Is “Closed Loop” shown on the malfunction diagnosis

instrument?


3

1. Turn the ignition switch to "LOCK".

2. Refer to data in “Freeze Frame/Failure mode” and

record the parameter.

3. Operate the vehicle under conditions of “Freeze

Frame/Failure mode” and “setting conditions of

DTC”.

Is “Closed Loop” shown on the malfunction diagnosis

instrument?


4

1. Disconnect the upstream oxygen (O2) sensor

connector.

2. Connect a jumper cable between the oxygen sensor

connector terminal 1 and the bonding.


Is signal voltage of the oxygen sensor shown on the

malfunction diagnosis instrument in line with the specified

value?


5

Check the oxygen sensor connector for inoperable

terminals or poor connection and repair if necessary.

Is reparation work needed?


6


2. Remove the jumper cable.

3. Measure the voltage between oxygen sensor

connector terminal 3 and the bonding.

Is the measured voltage of the oxygen sensor higher



7


2. Measure the voltage between pre-catalyst lambda

probe connector terminal 3 and the bonding.

Is the measured voltage of the oxygen sensor higher



8

Repair the wire between pre-catalyst lambda probe

terminal 1 and ECM terminal B_C1 and failures of

connector open or short-circuit to the bonding.



9

Repair the wire between oxygen sensor terminal 3 and

ECM connector terminal B_F2 and failures of connector

open or short-circuit to the bonding.





10


2. Replace the ECM.

3. Perform “Diagnosis system check-engine control

system”.


System OK

11 Replace the oxygen sensor.

Is the reparation work finished? Go to Step 12

12

1. Clear any DTC existing in the ECM.

2. Perform “Diagnosis system check-engine control

system”.


Go to Step 13

13 Check whether any other DTC is set.

Is there any DTC that has not been diagnosed? Go to "DTC List" System OK


6.4C.4.85 DTC P0643 High voltage of sensor supply voltage 1 circuit, P0642 Low voltage of

sensor supply voltage 1 circuit, P0653 High voltage of sensor supply voltage 2 circuit, and


Circuit description

ECM has four 5V reference voltage circuits. ECM supplies 5V reference voltage to each sensor. If any of the 5V

reference voltage circuit is short to the bonding or the power, all components connected to this 5V reference voltage

circuit will be affected. ECM will monitor voltages of the 5V reference voltage circuits.



Sensor supply voltages are beyond the range of 4.4-5.5V.








Aids for diagnosis

If a shared 5V reference voltage circuit is short to the bonding or the voltage, the rest of the 5V reference voltage

circuits may be affected.

The parameters of 5V reference voltages shown on the malfunction diagnosis instrument should be within the

range of 4.4-5.6V.


DTC P0643 High voltage of sensor supply voltage 1 circuit


1.




- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2.

Turn the ignition switch to “OFF” and disconnect all wiring

harness connectors of corresponding sensors with the

appropriate DTCs. See “Diagnosis aids”.

- Go to Step 3

3.

Turn the ignition switch to “ON” and test whether the

voltages between the following 5V reference voltage

circuits ans the bonding are within 4.4-5.6V.

Intake manifold absolute pressure sensor terminal;

Accelerator pedal position sensor terminal;

Accelerator pedal position sensor terminal;

Throttle body terminal;

EGR position sensor terminal;

-

Go to "Check of

powertrain

on-board

diagnostic

system"

Go to Step 4

4. Are the values higher than the specified range? - Go to Step 5 Go to Step 6

5.

Test whether 5V reference voltage circuits of all

corresponding sensors of the DTCs are short to the

power supply.


6.

Test whether 5V reference voltage circuits of all

corresponding sensors of the DTCs are short to the

earth.


7. Check corresponding sensor actuator circuits. -

8. Replace ECU. -


6.4C.4.86 DTC P0075 Intake VVT solenoid circuit open

Circuit description

The principle of engine variable valve timing (VVT) technology is to adjust the air intake (or exhaust) amount and

opening and closing time and angle of the valve in accordance with performance of the engine so as to make the optimal

air intake and promote fuel efficiency. Advantages: while effectively improve economical efficiency of the fuel, it can also

increase power of the engine as well as the engine torque at low and medium speeds.

Driver stage of the VVT control valve is controlled by a drive chip which can realize self diagnosis of driver stage through




Open circuit is found in ECM internal circuit.








Aids for diagnosis



Loosening terminal;


Broken keeper;




disconnect the ECU and VVT solenoid valve. Turn on the ignition switch and observe the voltage between ECU

control terminal ans the earth while moving connectors and wiring harness related with the VVT solenoid valve. If

the voltage varies, it indicates fault in this section.





DTC P0075 Intake VVT solenoid circuit open




Go to "Check of

powertrain

on-board

diagnostic

system"

2






DTC P0075?

- Go to Step 3

Go to

"Diagnostic

aids"

3 1. Shut the ignition switch.

2. Disconnect the intake VVT valve control circuit. - Go to Step 4 --

4

Connect a test lamp between VVT valve control circuit

wire (red) (main relay 87) and the earth. When battery

voltage is normal, can test lamp reach normal

brightness?


5


2. Test with a multimeter the voltage between ECU

control circuit of VVT valve control circuit wiring

harness (purple/white) (ECU pin B_J4) and the earth

to see whether the specified value is satisfied.


6 Test whether VVT valve control circuit is short to earth.

Is failure detected and resolved? - Go to Step 9 Go to Step 7

7

Check whether VVT valve control circuit wiring harness is

short to earth, short to power, open or of high resistance.

Check for poor connection between VVT valve control

circuit and ECU terminal plug pin.



8 Replace the VVT valve control circuit.


9



Is DTC reset?



6.4C.4.87 DTC P0076 Intake VVT solenoid short to earth

Circuit description









Short circuit to earth is found in ECM internal circuit.








Aids for diagnosis



Loosening terminal;


Broken keeper;





control terminal ans the earth while moving connectors and wiring harness related with the VVT solenoid valve. If






DTC P0076 Intake VVT solenoid short to earth




Go to "Check of

powertrain

on-board

diagnostic

system"

2






DTC P0076?

- Go to Step 3

Go to

"Diagnostic

aids"



4




brightness?


5







6 Test whether VVT valve control circuit is short to earth. Is

failure detected and resolved? - Go to Step 9 Go to Step 7

7









9



Is DTC reset?



6.4C.4.88 DTC P0077 Intake VVT solenoid short to power

Circuit description









Short circuit to power is found in ECM internal circuit.








Aids for diagnosis



Loosening terminal;


Broken keeper;





control terminal ans the earth while moving connectors and wiring harness related with the VVT solenoid valve.If






DTC P0077 Intake VVT solenoid short to power




Go to "Check of

powertrain

on-board

diagnostic

system"

2






DTC P0077?

- Go to Step 3

Go to

"Diagnostic

aids"



4




brightness?


5







6 Test whether VVT valve control circuit is short to earth.

Is failure detected and resolved? - Go to Step 9 Go to Step 7

7









9



Is DTC reset?



6.4C.4.89 DTC P0487 EGR Valve Driver Open-circuit

Circuit Description Engine control module monitors the input of the exhaust gas recirculation valve position to ensure that the valve correctly respond to the command of ECM. The linear exhaust gas recirculation valve is controlled with the open-circuit fault in the ignition timing driver and grounding circuit. The driver can detect the open-circuit fault of the ignition timing and grounding circuit. If the open-circuit fault occurs, the driver will send DTC P0487 signal to ECM. Conditions for setting trouble code An open circuit is found in ECM internal circuit. Actions taken when diagnostic trouble code is set







Aids for diagnosis



Loosening terminal;


Broken keeper;



14. ECM is equipped with an electronic pluggable and programmable read-only memory (EEPROM) and when ECM is

replaced, the new control module must be programmed.


DTC P0487 EGR Valve Driver Open-circuit

Step Action Value Yes No

1 Perform the “European on-board diagnostic (EOBD) system Check”.

Is the system check complete? –

Go to Step 2

Go to "Check of on-board diagnostic system"

2

1. Stop the engine and energize the ignition device. 2. Command exhaust gas recirculation between 0 to 10% with the malfunction diagnosis instrument and check if the electromagnetic coil is switched on and off under the corresponding command.

– Go to

"Diagnostic aids"

To Step 3

3

1. Disconnect the ignition switch 2. Disconnect the exhaust gas recirculation valve 3. Stop the engine and energize the ignition device. 4. Check the electromagnetic coil control circuit with the test lamp

which is reliably grounded. 5. Command exhaust gas recirculation between 0 to 10% with the

malfunction diagnosis instrument If the test lamp could be on or off according to command?

– Go to Step 4

Go to Step 5

4

1. Connect the test lamp to be between the electromagnetic coil control circuit and the grounding circuit. 2. Command exhaust gas recirculation between 0 to 10% with the malfunction diagnosis instrument and check if the electromagnetic coil is switched on and off under the corresponding command.

– Go to Step 8

Go to Step 10

5 Check if the test lamp flashes according to each command. – Go to Step 7

Go to Step 6

6 Test if the electromagnetic coil control circuit is shorted or open to ground. Is failure detected and resolved?

– Go to

Step 13 Go to Step 9

7 Test if the electromagnetic coil control circuit is shorted or open to ground. Is failure detected and resolved?

– Go to


8 Check if the exhaust gas recirculation valve has poor contact. Is failure detected and resolved?

– Go to


9 Check if the engine control module has poor contact. Is failure detected and resolved?

– Go to


10

Repair the electromagnetic coil circuit and check if the repair is completed. Go to

Step 13

11 Replace the exhaust gas recirculation valve and check if the operation is completed.

Go to

Step 13

12 Important note: When the engine control module is replaced, the new engine control module must be programmed. Replace the engine control module and check if the operation is finished.

Go to

Step 13

13 Record the fault and clear DTC with malfunction diagnosis instrument. Operate the vehicle according to the fault records and check if DTC is reset.

Go to Step 2

System OK.


6.4 C.4.90 DTC P0489 EGR Driver short to earth

Circuit Description Exhaust gas recirculation system (EGR) is to reduce nitrogen oxides (NOx) due to high-temperature combustion. The object to reduce nitrogen oxides can be achieved through returning a small amount of exhaust gas to the chamber. The concentration of the air/fuel mixture becomes dilute due to the return of the exhaust ga and then the temperature is lowered. The linear EGR valve in the system is designed according to the standard that accurately supplying exhaust gas to engine without occupying the volume of the intake manifold. The EGR valve controls the flow amount of the exhaust gas from the exhaust manifold into the intake manifold through the orifice (its valve pin opening is controlled by engine control module). ECM controls the valve pin opening through the intake air amount of the throttle position (TP) sensor and the intake air pressure (MAP) sensor. During the process of ECM controlling ignition signal, start the exhaust gas recirculation valve when considered necessary. This process can be monitored using the malfunction diagnosis instrument mounted on the exhaust gas recirculation system. ECM monitors the execution result of the command through feedback signal. EGR is provided with 5V reference voltage and the low reference voltage circuit is provided with grounding. Voltage signal will feed the valve pin opening of EGR valve back to ECM. This feedback signal also can be monitored by the malfunction diagnosis instrument, which also can provide the actual position of the valve pin opening of EGR valve. The actual position of EGR valve pin opening is generally close to the required or anticipated opening position. Diagnostic trouble code (DTC) is detected through the too high or too low voltage feedback from EGR valve position. Conditions for setting trouble code A circuit short to earth is found in ECM internal circuit. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises. The fault indicator light is lighten up after is the fault is detected out in 2 consecutive driving cycles. Conditions for turning off the MIL/clearing DTC If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.



Aids for diagnosis Check the following conditions: 15. ECU poor connection-check whether wiring harness connector exists:

Loosening terminal; Poor match connection; Broken keeper; Deformed or damaged terminal; Poor connection of terminal with the wire;

16 As the moisture is associated with the exhaust system, EGR valve may freeze at low temperature. And after the vehicle is started and the valve is heated, the problem will disappear. The actual position and expected position of the EGR valve of the low-temperature vehicle can be observed through the malfunction diagnosis instrument and then the fault position can be verified. Check if the diagnostic trouble code under low temperature is set through the record of “freeze fault state”. When judging if the temperature is low, you can refer to engine cooling water temperature (ECT).


DTC P0079 EGR driver short to earth Step Action Value Yes No

1. Check if the powertrain on-board diagnostic system inspection has been carried out.

—— Go to Step 2 Go to "Check of

powertrain on-board diagnostic system"

2

1) Turn on the ignition switch and keep the engine flameout. 2) Connect the malfunction diagnosis instrument. 3) Command the exhaust gas recirculation (EGR) valve to

open or close. Check if the EGR valve operation is consistent with the expected operation.


3

1) Turn on the ignition switch and keep the engine flameout. 2) Disconnect EGR valve electronic terminals. 3) Make the digital multimeter (DVM) grounded and probe

the signal of 5V reference voltage of the pin 4 corresponding to ZK14 (red) line.

If DVM reading similar is similar to the specified value?


4

Connect the 5V reference voltage of the pin 4 corresponding to ZK14 (red) line and the pin 3 corresponding to A_E1 (brown/yellow) to the signal voltage circuit. Check if the actual opening position of EGR valve is at the specified opening position.


5

1) Connect the test lamp to pin B. 2) Test the condition between EGR valve and 5V reference

voltage circuit. Check if the test lamp is on.

—— Go to Step 8 Go to Step 9

6

Test if the 5V reference voltage circuit and signal circuit have poor contact and improper stretching pin and repair it if necessary. If it is necessary to be repaired?

——


7

1) Connect the test lamp to pin B. 2) Test the condition between the pin 3 of the signal circuit

corresponding to A_E1 (brown/yellow) and EGR valve. Check if the test lamp is on.


8 Check if 5V reference voltage circuit of EGR valve is short to ground and repair it if necessary. Is it necessary to be repaired?


9 Check if 5V reference voltage circuit of EGR valve is open and repair it if necessary. Is it necessary to be repaired?


10 Replace EGR valve and check if the replacement is finished.

—— Go to Step 15 ——

11 Test if EGR valve signal voltage circuit is shorted to the ground and repair it if necessary. Is it necessary to be repaired?


12 Test if EGR valve signal voltage circuit is open and repair it if necessary. Is it necessary to be repaired?


13 1) Disconnect the ignition switch. 2) Replace ECM or not.

Is the replacement finished? —— Go to Step 15

——

14 Test if the relevant circuit has poor contact or improper stretching pin and repair it when necessary. Is it necessary to be repaired?


15

1) Clear the diagnostic trouble code with the malfunction diagnosis instrument.

2) Start the engine and keep it idling at the normal temperature.

3) Operate the vehicle under the condition setting the diagnostic trouble code in the supporting document.

Check if the malfunction diagnosis instrument indicates that the diagnosis has run and passed.


16 Check if there is undiagnosed additional diagnostic code. Check if there is transferred diagnostic trouble code which is undiagnosed.

—— Go to the

corresponding DTC list

System OK.


6.4C.4.91 DTC P0490 EGR Driver short to power

Circuit Description Exhaust gas recirculation system (EGR) is to reduce nitrogen oxides (NOx) due to high-temperature combustion.

The object to reduce nitrogen oxides can be achieved through returning a small amount of exhaust gas to the chamber. The concentration of the air/fuel mixture becomes dilute due to the return of the exhaust ga and then the temperature is lowered.

The linear EGR valve in the system is designed according to the standard that accurately supplying exhaust gas to engine without occupying the volume of the intake manifold. The EGR valve controls the flow amount of the exhaust gas from the exhaust manifold into the intake manifold through the orifice (its valve pin opening is controlled by engine control module). ECM controls the valve pin opening through the intake air amount of the throttle position (TP) sensor and the intake air pressure (MAP) sensor. During the process of ECM controlling ignition signal, start the exhaust gas recirculation valve when considered necessary. This process can be monitored using the malfunction diagnosis instrument mounted on the exhaust gas recirculation system.

ECM monitors the execution result of the command through feedback signal. EGR is provided with 5V reference

voltage and the low reference voltage circuit is provided with grounding. Voltage signal will feed the valve pin opening of EGR valve back to ECM. This feedback signal also can be monitored by the malfunction diagnosis instrument, which also can provide the actual position of the valve pin opening of EGR valve. The actual position of EGR valve pin opening is generally close to the required or anticipated opening position.

Diagnostic trouble code (DTC) is detected through the too high or too low voltage feedback from EGR valve

position.

Conditions for setting trouble code A circuit short to power is found in ECM internal circuit.


It will enter into failure memory immediately a malfunction arises. The fault indicator light is lighten up after is the fault is detected out in 2 consecutive driving cycles.

Conditions for turning off the MIL/clearing DTC If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL. When 40 consecutive pre-heating cycles run fault-freely, trouble code will be cleared. Trouble code can be cleared with a malfunction diagnosis instrument.

Aids for diagnosis Check for the following situations: 1. ECU poor connection-check whether wiring harness connector exists: Loosening terminal; Poor match connection; Broken keeper; Deformed or damaged terminal; Poor connection of terminal with the wire;

2. As the moisture is associated with the exhaust system, EGR valve may freeze at low temperature. And after

the vehicle is started and the valve is heated, the problem will disappear. The actual position and expected

position of the EGR valve of the low-temperature vehicle can be observed through the malfunction diagnosis

instrument and then the fault position can be verified. Check if the diagnostic trouble code under low

temperature is set through the record of “freeze fault state”. When judging if the temperature is low, you can

refer to engine cooling water temperature (ECT).


DTC P0080 EGR driver short to power

Step Action Value Yes No

1.

Perform the “European on-board diagnostic (EOBD) system

Check”.


– Go to Step 2

Go to "Check of on-board diagnostic system"

2

1. Stop the engine and energize the ignition device. 2. Command exhaust gas recirculation between 1 to 100%

with the malfunction diagnosis instrument and check if the electromagnetic coil is switched on and off under the corresponding command.

– Go to

“Diagnostic aids”

Go to Step 3

3

1. Disconnect the ignition switch 2. Disconnect the exhaust gas recirculation valve 3. Stop the engine and energize the ignition device. 4. Check the electromagnetic coil control circuit with the

test lamp which is reliably grounded. 5. Command exhaust gas recirculation between 0 to 10%

with the malfunction diagnosis instrument. Check if the test lamp is ON or OFF according to

command.


4

1. Connect the test lamp to be between the electromagnetic coil control circuit and the grounding circuit.

2. Command exhaust gas recirculation between 0 to 10% with the malfunction diagnosis instrument and check if the electromagnetic coil is switched on and off under the corresponding command.


5 Check if the test lamp flashes according to each command. – Go to Step 7 Go to Step 6

6 Test if the electromagnetic coil control circuit is shorted or open to ground.



7 Test if the electromagnetic coil control circuit is short to earth or open. Is failure detected and resolved?


8 Check if the exhaust gas recirculation valve has poor contact.



9 Check if the engine control module has poor contact. Is failure detected and resolved?


10 Repair the electromagnetic coil circuit and check if the repair is completed.

Go to Step 13

11 Replace the exhaust gas recirculation valve and check if the operation is completed.

Go to Step 13

12

Important: When the engine control module is replaced, the new engine control module must be programmed.

Replace the engine control module and check if the operation is finished.

Go to Step 13

13

Record the fault and clear the trouble code with the malfunction diagnosis instrument.

Operate the vehicle and check if the diagnostic trouble code is reset in the fault record.

Go to Step 2 System OK.


6.4C.4.92 DTC P0506 Too low speed by idle speed control and DTC P0507 Too high speed by

idle speed control

Circuit description

Throttle actuator control (TAC) machine is a DC one and a constituent part of the throttle body. TAC machine drives the

throttle. ECM, based on the input of the throttle position sensor, controls the TAC machine. ECM controls the idle speed

based on the multiple inputs. ECM instructs the TAC machine to close or open the throttle so as to maintain the

expected idle speed.


If engine speed is150rpm below the target idle speed, set the fault of DTC P0506.

If engine speed is 200rpm beyond the target idle speed, set the fault of DTC P0507.








Aids for diagnosis

Check the following parts:

For P0506:

Too many deposits in the throttle body. Refer to the “Cleaning of the throttle body”.

The exhaust system is jammed.

Engine speed is limited by mechanical problems.

There are parasitic loads on the engine, for example: the failures of the transmission or driven accessories of the

transmission belt.

- Any failure detected should be repaired as needed.

For P0507:

Vacuum leakage;

The throttle cannot be properly closed;

Check whether the crankcase ventilation system functions well.


- Arrangement of the positive crankcase ventilation (PCV) system;

- Vacuum leakage of the PCV system - See “Check/Diagnosis of the crankcase ventilation system”.

- Any failure detected should be repaired as needed.


6.4C.4.93 DTC P0504 Inappropriate brake light and brake signals relativity

Circuit description

The service brake switch consists of two circuits. One is the normally open brake light switch circuit and the other is the

normally close brake light switch circuit. When you step down the service brake pedal, the normally open circuit inside

the service brake switch will close and the brake light circuit will be connected. Brake light will then be lit and ECM will

take this signal as a brake signal. The normally close circuit inside the service brake switch will open and ECM will take

this signal as brake signal of the other circuit. The two brake signals ensure driving safety.


Inconformity of the brake light signal (the normally open) and brake signal (the normally close) lasts for more than

600s.









DTC P0504 Inappropriate brake light and brake signal relativity


1.




- Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

system"

2. 1. Ignition switch is in the state of OFF;

2. Disconnect service brake switch plug connectors. - Go to Step 3 -

3.

Measure the continuity between the two pins (the

corresponding pins of the white line and the black line) of

the normally close switch with buzzer of a digital

multimeter to see whether it’s connected when the brake

pedal is free and it’s open circuit when the pedal is

stepped down?


4.

Measure the continuity between the two pins (the

corresponding pins of the green/black line and the green

line) of the normally open switch with buzzer of a digital

multimeter to see whether it’s open circuit when the

brake pedal is free and it’s connected when the pedal is

stepped down?


5. Disconnect the ECM terminal plug connector. - Go to Step 6 -

6.

Test whether it’s connected between wiring harness

(white line) pin of service brake switch terminal and

corresponding wiring harness (green/orange) of ECM

A_E2 pin.


7

Test whether it’s connected between the wiring harness

pin of service brake switch terminal (black line) and the

bonding.


8

Test whether it’s connected between wiring harness pin

of service brake switch terminal (green line) and

corresponding wiring harness (green/white) of ECM

A_F4 pin.


9

Test whether voltage between wiring harness

(green/black line) pin of service brake switch terminal

and the bonding.

About 12V Go to Step 12 Go to Step 10

10

Check the access line for short circuit, open circuit or

high resistance. Check for poor connection of ECU

terminal or sensor terminal plug pin.



11 Replace the service brake switch assembly. Go to Step 13

12 Replace the ECM. Go to Step 13

13


instrument.



Is DTC reset?



6.4C.4.94 DTC P2299 Contradictory positions of the break and the accelerator pedal

Circuit description

When brake signal is detected by the ECM and if the accelerator pedal position signal is not within the specific range,

this DTC will be configured.



Brake signal is detected by the ECM.

Vehicle speed signal is over 10 Km/h.

The value of the accelerator pedal is over 4.98%.

Engine speed is more than 1216 rpm.








Diagnosis and maintenance 1. Check if the voltage of the electrical accelerator pedal sensor 1 is between 0.56-4.78V, the voltage of the electrical

accelerator pedal sensor 2 is between 0.28-2.39V. Step on accelerator, the heavier the accelerator, the higher the sensor voltage of the accelerator pedal.

2. Check if the wire connection between the sensor 1 signal end (white red) of accelerator pedal and the ECU pin (B_D3) or between the sensor 2 signal end(white blue) of accelerator pedal and the ECU pin (B_B1) are conducted, if not, please replace the line.

3. Check if the brake switch is worn or broken. 4. Replace ECU, clear the trouble code, and check if the trouble code reappears after several driving cycles.


6.4C.4.95 DCT P0406 EGR valve position signal high, DTC P0405 EGR valve position signal low Circuit description There are 3 pins connected to the EGR position sensor, namely 5V sensor (pin A_C4), sensor grounding (pin B_H2) and sensor signal terminal (pin A_E1). The sensor voltage will display the corresponding value of EGR open degree. Set DTC P0406 when the sensor voltage is larger than 4.78V. Set DTC P0405 when the sensor voltage is lower than 0.24V. Conditions for setting trouble code EGR position sensor voltage >4.78V EGR position sensor voltage <0.24V Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.

Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 1 continuous driving cycle. Conditions for turning off the MIL/clearing DTC If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.



Diagnose and maintenance 1. Check if the accumulator voltage is between 11V and 16V with a multimeter. The voltage value of accumulator will

impact the EGR position sensor’s voltage directly. 2. Check if the voltage between the EGR sensor output (blue/brown) and the ground terminal is 5V with a multimeter,

to judge if there is any short circuit in the sensor. Please replace the EGR if there is a short circuit. If not, please check if the wire connection between EGR position sensor signal terminal (brown/yellow) and ECU pin (A_E1) is conducted. If not, replace the line

3. Check if the voltage of EGR position sensor signal is between 0.24V-4.78V with a diagnostic instrument.


6.4C.4.96 DTC P0135 unreasonable heating circuit of upstream oxygen sensor Circuit description The upstream oxygen sensor is consisted of a heating circuit and a signal circuit. The normal work temperature of the front oxygen sensor is around several hundred degrees, the oxygen sensor must provide an accurate signal to ECU while the engine is starting ,moving and driving .The front oxygen sensor has to reach up a high temperature in a short time before the engine starts up ,so that a heating circuit is need to be provided .The heating circuit failure will affect the signal voltage of the oxygen sensor, which will directly influence the measurement of oxygen concentration in exhaust, causing the performance of oxygen sensor to decrease. Conditions for setting trouble code Internal resistance of the front oxygen sensor>10000Ω Number of error reports detected >20 Exhaust temperature of the front oxygen sensor <700℃ Heating duty ratio should be around 1.17% to 99.6% Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.

Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 2 continuous driving cycles. Conditions for turning off the MIL/clearing DTC If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.


Diagnose and maintenance 1. Disconnect the oxygen plug, detect the output end of oxygen sensor (red line) and the heating control terminal

(purple/yellow line), measure the resistance value of the oxygen sensor heating circuit whether is between 4Ω-20 or not. If not, replace the oxygen sensor.

2. Check if the voltage value of the oxygen sensor changes between 0.4-0.9V with diagnostic device. If not, check if the wire connection between the oxygen sensor signal end (red/yellow) and the ECU pin (B_C1) is conducted. If not, replace the circuit.

3. Check if the voltage of the output end of the front oxygen sensor (red) and the grounding end (green/white line) is 12V, and if not, check the accumulator voltage.

4. Replace ECU, clear the trouble code, and check if the trouble code reappears after several driving cycles.


6.4C.4.97 DTC P0134 preparation of upstream oxygen sensor uncompleted Circuit description After starting the engine, ECU will automatically check the output voltage of oxygen sensor. If the voltage value is lower than 0.48V in the regulated detection time, set trouble code P0134 and ECU will consider the oxygen sensor as not working status, which might be caused by ECU fault, oxygen sensor fault, or oxygen sensor circuit fault, etc. Conditions for setting trouble code

Exhaust gas temperature of the front oxygen signal sensor >350℃

Signal voltage of the front oxygen sensor is between 0.35V and 0.498V Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.


Conditions for turning off the MIL/clearing DTC If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.



Diagnosis & Maintenance 1. Check if the voltage between the front oxygen sensor (red line) and the oxygen sensor grounding end (green /white

line) is 12V with a multimeter. If not, check if the accumulator voltage is between 11V and 17V. 2. Check if the signal voltage of oxygen sensor is variable between 0.4-0.9V with diagnostic unit. If not, check if the

connection between the signal end of oxygen sensor (red/yellow) and ECU pin (B_C1) is conducted with a multimeter. If not , replace the line.

3. Check if the heating resistance of the oxygen sensor is about 4-20Ω with a multimeter. If the sensor resistance is over 1KΩ, replace the oxygen sensor.

4. Check if the exhausting system is leaking and resulting that the front oxygen sensor heating time is too long. 5. Replace ECU, clear the trouble code, and check if the trouble code reappears after several driving cycles


6.4C.4.98 DTC P2158 unreasonable wheel speed sensor signal

Circuit description The electro-magnetic inductive wheel speed sensor mainly consists of sensor head and magnetic wire magnetic coil. When the gear ring rotates, the tooth crest and tooth space directs to the magnetic core by turns, and the magnetic flux alternates and changes quickly thus producing alternating voltage in the induction coil. The frequency of the alternating voltage will vary by direct proportion according to the wheel. The electric control device can determine the wheel rotating speed, the reference speed of the vehicle, etc. via dealing with the voltage pulse frequency inputted by wheel speed sensor. Conditions for setting trouble code Vehicle speed is 0 Engine water temperature >0 Engine speed >2000r Air inflow >202mg/str Idling time >30s

Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.




Diagnosis & Maintenance 1. Remove the plug of the wheel speed sensor, use the multimeter to detect the on/off of the sensor internal circuit

(pins corresponding to lines B_E1 and B_F1). 2. Check if there is an open circuit or short circuit between the connection line B_E1 and line B_F1 of the wheel speed

sensor. 3. Replace the wheel speed sensor, clear the trouble code, read the trouble code again after several driving cycles to

see if the trouble code reappears.


6.4C.4.99 DTC P0011 Camshaft position sensor offset in steady working condition Circuit description The camshaft position sensor is used for collecting the position signal of the air distribution camshaft and input ECU to enable ECU to identify the compression TDC (Top Dead Center) of air cylinder 1, thus conducting the sequential fuel injection control, ignition timing control and deflagration control. Besides, the camshaft position sensor is also used for identifying the first ignition time of the engine start. When there is certain deviation between the actual camshaft position and the theoretical camshaft position, set up fault P0011. Conditions for setting trouble code Camshaft position sensor >4.125 Camshaft offset deviation integration >25





Diagnosis & Maintenance 1. Use a multimeter to check if the voltage between camshaft position sensor power supply (purple/white) in the air

intake side and the sensor grounding (grey) is 5V. If not, check if the accumulator voltage is 13-17V. If yes, replace the camshaft position sensor.

2. Use a multimeter to check if the wire between camshaft position sensor signal end (blue/black) and ECU pin (B_C3) is conducted. If not, replace the circuit.

3. Replace engine oil and ECU respectively, clear the trouble code, read the trouble code after several driving cycles to check whether the P0011 reappears again.


6.4C.4.100 DTC P2118 throttle position signal deviation too large Circuit description Installed in the throttle, the throttle position sensor can convert the open angle of the throttle into voltage signal and send to ECU, so as to control the fuel-injection amount according to the different open degrees of the throttle. Throttle position sensor 1 and 2 are positioned within the throttle body assembly. The sensor has circuits of the flowing: One reference voltage of 5V One low level reference voltage circuit Two signal circuits When there is a failure in the throttle electric motor or throttle position sensor, the deviation of the throttle position signal may be too large. Set up trouble code P2118 in this case. Conditions for setting trouble code ECU detects that the throttle position control is beyond limits. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.

Malfunction indicating lamp (MIL) will be lit when malfunction is detected in 1 continuous driving cycle.. The engine is idling. Conditions for turning off the MIL/clearing DTC If no malfunction in 3 consecutive driving cycles occurs, turn off the MIL.



Diagnosis & Maintenance 1. When the engine is in idling condition, use a multimeter to detect whether there is electricity in the throttle control

circuit (the circuit between pin A_G1 and pin A_F1) to determine the breakover in the interior of the throttle electric motor. If there is no current, replace the throttle assembly.

2. Use a multimeter to detect whether the voltage between the throttle position sensor power supply terminal A_D4 (red/white) and the wire corresponding to the grounding terminal A_D2 (grey/white) is 5 V, step on the accelerator pedal, use the diagnosis instrument to detect whether the voltage of the throttle position sensor 1 varies between 0.25-4.75V, whether the voltage of the throttle position sensor 2 varies between 4.75V-0.25V and the sum of these two voltages is always 5V and thus remaining complementary. If not, replace the throttle assembly.

3. Use a multimeter to detect whether the circuit among throttle position sensor 1 signal terminal (white/yellow), ECU pin (A_F3)/ throttle position sensor 2 signal terminal (brown/white) and ECU pin (A_C1) is conducted. If not, replace the throttle assembly.

4. Replace ECU, clear the trouble code, and check whether the trouble code reappears again after several driving cycles.


6.4C.4.101 DTC P2096 fuel correction too dilut/ P2097 fuel correction too dense Circuit description Fuel correction consists of short term fuel correction and long term fuel correction; the former is caused by the failure of one sensor in short time and the latter is the comprehensive result of several control units. The long term fuel correction has more reference significance than the short term fuel correction. When there is a failure in one sensor or system, the deviation in the fuel correction may exceed over ±15%. Then it is likely to set up DTCs P2096 and P2097. Conditions for setting trouble code 1 The engine is in steady working condition 2 The fuel correction deviation excesses ±15% Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.




Diagnosis & Maintenance 1 Check whether there is leak in the air intake system thus resulting in insufficient air intake. 2 Measure whether the fuel pressure is around 350KPA. If not, check fuel system. 3 Detect whether there is failure in three-way catalyst. If yes, replace the three-way catalyst. 4 Detect the fuel quality, for poor fuel quality will also result in excessive fuel correction deviation.


6.4C.4.102 DTC P0606 processor communication error Circuit description Processor communication error refers to the abnormal signal connection between ECU and control units. This trouble code may be caused by the refit of the non-original accessories or ECU internal circuit failure. Conditions for setting trouble code ECU interior automatically detects the processor communication error. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.




Diagnosis & Maintenance 1 Read the corresponding data flow of oxygen sensor, air intake temperature sensor and throttle position sensor etc.,

observe the unusual data flow and conduct statistical analysis, and carry out single-point exclusion for each sensor. 2 The processor communication error is most likely caused by the failure of ECU itself. Replace ECU and clear the

trouble code, and then check whether the trouble code reappears again after several driving cycles


6.4C.4.103 DTC P2120 accelerator pedal disconnection diagnosis Circuit description In the Electronic Throttle Control (ETC) system, the function of the Accelerator Pedal Position (APP) sensor is to send APP to ECU in the form of electric signal. According to various sensor signals such as engine speed, gears, throttle position, air-conditioning energy consumption etc., ECU calculates the overall torque the entire vehicle requires, obtains the optimal opening of the throttle through compensating the throttle corner expectation value, and sends the corresponding voltage signal to the drive circuit module, driving and controlling the electric motor to make the throttle reach to the optimal opening position. The throttle position sensor reports the opening signal of the throttle back to the throttle control unit, forming the closed loop position control. Conditions for setting trouble code ECU interior detects accelerator pedal disconnection diagnosis. Actions taken when diagnostic trouble code is set It will enter into failure memory immediately a malfunction arises.




Diagnosis & Maintenance 1 Use a multimeter to detect whether the voltage between accelerator pedal position sensor power supply 1 (green)

and grounding terminal/between accelerator pedal position sensor power supply 2 (red) and grounding terminal is 5V. Use the diagnostic unit to detect whether the signal voltage of accelerator pedal position sensor 1 is between 0.56-4.78V and whether the signal voltage of accelerator pedal position sensor 2 is between 0.28V-2.39V. If not, replace the accelerator pedal position sensor.

2 Use a multimeter to detect whether the circuit between accelerator pedal position sensor signal 1 (white/red) and ECU pin (B_D3)/ between accelerator pedal position sensor signal 2 (white/blue) and ECU pin (B_B1) is conducted. If not, replace the line.

3 Replace ECU, clear the trouble code and check whether the trouble code reappears again after several driving cycles


6.4C.4.104 DTC P0141 unreasonabl heating circuite of downstream oxygen sensor Circuit description The function of oxygen sensor is to measure the oxygen content in the engine exhaust gas to correct the fuel-injection amount so as to make the motor obtain the optimal air-fuel ratio. The electronic control unit continuously monitors the oxygen sensor heater to make sure there is no open circuit, short circuit or over consumption of the current. This trouble code will occur when the current consumption exceeds the standardized limits or there is open circuit or short circuit detected. Conditions for setting trouble code Back oxygen sensor internal resistance >10000Ω Errors detected >20 times

Exhaust temperature of back oxygen sensor <750℃





Diagnosis & Maintenance 1 Use a multimeter to detect whether the voltage between the back oxygen sensor heating power (red) and the

grounding terminal is 12 V. Use a diagnostic unit to read whether the signal voltage of back oxygen sensor is between 0.4V-0.9V. Use a multimeter to measure whether the oxygen sensor heating resistance is between 4Ω-20Ω. If not, replace oxygen sensor.

2 Use a multimeter to detect whether the circuit between the oxygen sensor signal terminal (red/green) and ECU pin (B_A3) is conducted. If not, replace the line.

3 Check whether there is problem like corrosion in the back oxygen sensor. If yes, replace the back oxygen sensor and clear this trouble code.

4 Replace ECU, clear the trouble code and check whether the trouble code reappears after several driving cycles.


6.4C.4.105 DTC P060C main controller monitoring fault Circuit description There are two sets of independent hardware in the motor ECU, using for function module and monitor module respectively. The function module is used for receiving and tackling the sensor signals, controlling the executor, and also checking the normal function of the monitor module, while the monitor module is only used for checking the normal work of the function module. Conditions for setting trouble code ECU interior automatically detects the main controller monitoring fault.






Diagnosis & Maintenance Clear the trouble code and check whether the trouble code reappears after several driving cycles. If yes, replace the ECU.


6.4C.4.106 DTC P061A reasonability monitoring fault of required torque and actual torque P061B actual or required torque exceeding the allowable value. Circuit description There are two independent sets of hardware in the motor ECU, using for function module and monitor module respectively. The function module is used for receiving and tackling the sensor signals, controlling the executor, and also checking the normal function of the monitor module, while the monitor module is only used for checking the normal work of the function module. When ECU detects that the required torque and actual torque are unconformable, set up trouble code P061A; set the trouble code P061B when the actual or required torque exceeds the limits. Conditions for setting trouble code The deviation between the required torque and the actual torque exceeds the limits. The actual or required torque exceeds the limits.





Diagnosis & Maintenance 1 Detect whether there is problem like leak in the air intake system thus causing the decrease of the air intake. If yes,

replace the air intake system. 2 Use a multimeter to measure whether the resistance of the engine coolant temperature sensor is between

2.5KΩ-4KΩ (under normal temperature). If not, replace temperature sensor. If yes, use a multimeter to detect whether the circuit between the temperature signal terminal (blue/black) and ECU pin (A_D3) is conducted. If not, replace the circuit.

3 Use a multimeter to measure whether the resistance of the crankshaft position sensor is between 1.2KΩ-1.6KΩ, and the voltage between power supply output terminal (red) and the grounding terminal is between 4.75V-5.25V. If not, replace crankshaft position sensor. If yes, use a multimeter to detect whether the circuit between the signal terminal (blue/yellow) of the crankshaft position sensor and the ECU pin is conducted. If not, replace circuit.

4 Replace ECU, clear the trouble code and check whether the trouble code reappears after several driving cycles.


6.4C.4.107 Symptom

Important preliminary checks before starting

Before using the symptom table:

1. Perform the "Check of powertrain on board diagnostic (OBD) system" and verify all of the following items:

The ECM and Malfunction indicating lamp (MIL) are operating correctly.

There are no DTCs stored.

The scan tool data is within the normal operating range. Refer to the "List of scan tool data".

2. Verify the complaints of customers.

3. Perform the visual inspection. Locate the correct symptom in the list at the end of this section. Follow the

procedures in the appropriate diagnostic table. If the problem cannot be duplicated, also refer to "Intermittent

conditions".

Visual inspection

Several of the symptom procedures call for a careful visual inspection. This can lead to correcting a problem without

further checks and can save valuable time. This check should include the following items:

Inspect the engine control unit (ECU) grounds for being clean, tight, and in their proper location.

Inspect vacuum hoses for splits, kinks, and proper connections, as shown on the vehicle emission control

information label. Inspect thoroughly for any type of leak or restriction.

Inspect the air intake ducts for collapsed or damaged areas.

Inspect for air leaks at the throttle body mounting area.

Inspect the wiring harness for poor connections, pinches, cuts, or other damages.

Inspect for loose, damaged, or missing sensors/components.

Use the following tables when diagnosing symptom complaints:

Starting difficulty

Surges/chugging

Lack of power, sluggishness or sponginess

Knock/spark knock

Hesitation, sag and stumble

Cuts out and misses

Poor fuel economy

Rough, unstable or incorrect idle and stalling

Ignition Off, dieseling and run-on of throttle rear engine

Backfiring

Check of restricted exhaust system


6.4C.4.108 Intermittent conditions

Check Action

Definition: The problem is not currently present but is indicated in DTC history. There is a customer complaint, but the symptom cannot currently be duplicated (if the problem is not DTC related).

Preliminary checks Refer to "Important Preliminary checks" in "Symptoms", before starting. The fault must be present to locate a problem using the DTC table. If a fault is intermittent, the use of DTC tables may result in the replacement of good parts.

Check of harness/connector

Many intermittent open or shorted circuits come and go with harness/connector movement caused by vibration, engine torque, bumps/ rough pavement, etc. Inspect for this type of condition by performing the applicable procedure from the following list: ● Move related connectors and wiring harnesses while monitoring the appropriate scan

tool data. ● Move related connectors and wiring harnesses with the component commanded on (and

off) with the scan tool. Observe the component's operation. ● With the engine running, move related connectors and wiring harnesses while

monitoring the engine operation. If the harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. Refer to the "Electrical connections or wiring" in this table.

Snapshot of scan tool The scan tool can be set up to take a snapshot of the parameters available. The snapshot function records live data over a period of time. The recorded data can be played back and analyzed. The scan tool can also graph parameters singly or in combinations of parameters for comparison. The snapshot can be triggered manually at the time the symptom is noticed, or set up in advance to trigger when a DTC sets. An abnormal value captured in the recorded data may point to a system or component that needs to be investigated further.

Electrical connections and wiring

Poor electrical connections/terminal tension or wiring problems cause most intermittent problems. Perform a careful inspection of the suspected circuit for the following: Inspect for poor mating of the connector halves, or terminals not fully seated in the

connector body (backed-out). Inspect for improperly formed or damaged terminals. Test for poor terminal tension. Inspect for poor terminal-to-wire connections including terminals crimped over insulation.

This requires removing the terminal from the connector body to test. Inspect for corrosion/water intrusion. Pinched, cut or rubbed through wiring. A misrouted harness that is too close to high voltage/high current devices such as

secondary ignition components, motors, and generator etc. These components may induce electrical noise on a circuit that could interfere with the normal circuit operation.

Improper installation of non-factory (aftermarket) adds on accessories.

IntermittentMalfunction indicating lamp (MIL) with no DTCs

The following conditions may cause an intermittent MIL and no DTCs: Electrical system interference caused by a malfunctioning relay, ECU driven solenoid, or

switch. They can cause a sharp electrical surge. Normally, the problem will occur when the malfunctioning component is operating.

Improper installation of non-factory (aftermarket) adds on accessories such as lights, radios, motors, etc.

TheMalfunction indicating lamp (MIL) circuit intermittently shorted to ground. Poor ECU grounds.

Loss of DTC memory In order to test for loss of DTC memory, perform the following tests: 1. Disconnect the ECT sensor. 2. Start the engine. 3. Monitor the DTC status for the DTC using a scan tool. 4. Allow the engine to idle until the DTC diagnostic runs. 5. Turn the key to OFF and wait for at least 30seconds. 6. Turn ON the ignition. 7. Monitor the scanning instrument for DTCs. The ECU should store and retain this information in memory even after turning off the ignition for at least 30seconds (The information should be stored indefinitely as long as the ECU battery feed and ground circuits are uninterrupted). If the DTC info is not retained, and the ECU power and grounds are OK, the ECU is malfunctioning.

Additional checks Test for an open diode across the A/C compressor clutch and for other open diodes. Improper installation of non-factory (aftermarket) add on accessories such as lights, radios, motors, etc. Test the generator for a bad rectifier bridge that maybe allowing the DC noise into the electrical system.


6.4C.4.92 Starting difficulty

Check Action

Definition: Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.

Preliminary checks Refer to the "Check of powertrain on-board diagnostic (OBD) system".

Refer to the "Intermittent Conditions" before starting.

Search for bulletins.

Sensor/system Inspect the engine coolant temperature (ECT) sensor for being shifted in value. Connect

a scan tool and compare the ECT with the intake air temperature (IAT) on a cold engine.

The ECT and IAT should be within ±3°C(5°F)of each other. Check the resistance of the

ECT sensor if the temperature is out of range with the IAT sensor. If the ECT sensor

resistance is not within the specification, refer to the "Engine coolant temperature (ECT)

sensor circuit low voltage" or the "Intake air temperature (IAT) sensor circuit high

voltage".

Inspect for the crankshaft position sensor on the scan tool. If it is not responding, inspect

the sensor feed circuit.

Inspect the MAP sensor for proper installation and connection.

Using a scan tool, check the idle air control (IAC) operation. Refer to the "Diagnosis of

idle air control system".

Fuel system Inspect the fuel pump relay circuit for proper operation. Refer to the "Diagnosis of fuel

pump electrical circuit".

Inspect for too low fuel pressure. Refer to the "Test of fuel system pressure".

Inspect for faulty fuel injectors. Remove the fuel injectors, and inspect the fuel injectors

for leaks or for restrictions by using the special clean and analytic instrument.

Inspect for contaminated fuel. Refer to "Alcohol/contaminants" in "Fuel diagnosis".

Ignition system If the spark is not present at the plugs, inspect for the following conditions:

Inspect the coils for cracks, carbon tracking/arcing or a resistance value outside the

specified range. The coil resistance is 11-15 kilo ohms.

Inspect the spark plug wires for signs of arcing/cross firing, cracks, carbon tracking, plug

boot damage, pinched, improper routing or a resistance value outside the specified

range.

Important: Spraying the secondary ignition wires with a light mist of water may help locate

an intermittent problem. Ignition components will arc to ground when a secondary

component is faulty.

Defective module

Ignition system wiring - loose ignition module feed or ground connection, or damaged

system wiring.

Remove the spark plugs and inspect for the following:

Fouled plugs

Cracks

Wearing

Improper gap

Burned or damaged electrodes

Correct model

If the spark plugs are gas or oil fouled, the cause of the fouling must be determined before

replacing the spark plugs.

Engine mechanical Excessive oil in combustion chamber - leaking valve seals.

Too low cylinder compression - refer to "Engine compression test" in "Engine mechanical".

For incorrect basic engine parts, inspect the following:

Cylinder head

Camshaft and valve train components

Pistons, etc.


6.4C.4.110 Surges/chugging

Check Action

Definition: Engine power variation under steady throttle or constant speed. Feels like the vehicle speeds up and slows

down with no change in the accelerator pedal.


Refer to the "Intermittent conditions".


Sensor/system Inspect the heated oxygen sensors. The heated oxygen sensors should respond quickly

to different throttle positions. If not, inspect the HO2S for silicon and other contaminants

from fuel or use of improper sealant. The sensors may have a white powdery coating.

Silicon contamination causes a too high but false HO2S signal voltage (too rich exhaust

indication). Refer to "Silicon contamination of heated oxygen sensors notice". The PCM

will reduce the amount of fuel delivered to the engine, causing a severe drivability

problem.

Inspect MAP related wiring.

Fuel system Inspect the fuel pressure. Refer to the "Test of fuel system pressure".

Inspect for contaminated fuel. Refer to the "Alcohol/contaminants" in the "Fuel

diagnosis".

Ensure each injector harness is connected to the correct injector/ cylinder.



specified range. The coil resistance is 11-15 kilo ohms


boot damage, pinched, improper routing or a resistance value outside the specified

range.

Important note: Determine the intermittent faults. If there is fault with the secondary ignition

components, sparks will be generated by the ignition components towards the grounding.

Defective ignition module


system wiring.


Fouled plugs

Cracks

Chafing

Improper gap


Correct model



Additional checks Inspect the exhaust system for possible restriction:

Inspect the exhaust system for damaged or collapsed pipes.

Inspect the mufflers for heat distress or possible internal failure.

Inspect for possible plugged three-way catalytic converter by checking the exhaust

system back pressure. Refer to the "Check of restricted exhaust system".


6.4C.4.111 Lack of power, sluggishness or sponginess

Check Action

Definition: The engine delivers less than expected power. There is little or no increase in delivered power when the

accelerator pedal is applied.


Inspect the coils for cracks, carbon tracking/arcing or a resistance value outside the specified

range. The coil resistance is 11-15 kilo ohms


boot damage, pinched, improper routing or a resistance value outside the specified range.

Important: Spraying the secondary ignition wires with a light mist of water may help locate an

intermittent problem. Ignition components will arc to ground when a secondary ignition



Ignition system wiring - loose ignition module feed or ground connection, or damaged system

wiring.


Fouled plugs

Cracks

Chafing

Improper gap


Correct model




Too low cylinder compression.


Camshaft

Cylinder head

Pistons, etc.

Additional checks Inspect the exhaust system for possible restriction. Inspect the following conditions:


Inspect the mufflers for heat distress or possible internal failure.

Inspect for possible plugged three-way catalytic converter. Refer to the "Exhaust Leakage" in

the "Check of engine exhaust and restricted exhaust system".

Inspect the clutch for proper operation.


6.4C.4.112 Knock/spark knock

Check Action

Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that

changes with throttle opening.


Refer to the "Intermittent conditions" before starting.


Fuel system Inspect the too low fuel pressure. Refer to the "Fuel system pressure test".

Inspect for contaminated fuel. Refer to the "Alcohol/contaminants" in the "Fuel diagnosis".

Ignition system Inspect the spark plugs for proper heat value. Refer to the "Spark plug Usage" in the "Engine

electrical".

Engine cooling

system

Inspect for obvious overheating problems:

Too low engine coolant.

Restricted air flow to radiator, or restricted water flow through radiator.

Inoperative electric cooling fan circuits.

Correct coolant solution should be a 48/52 mix. Refer to the "Coolant description" in the

"Engine cooling".


Too low cylinder compression - Refer to the "Engine compression test" in the "Engine

mechanical".

Excessive carbon buildup in the combustion chambers. Clean the chambers with top engine

cleaner. Follow instructions on can.


Camshaft

Cylinder head

Pistons, etc.


6.4C.4.113 Hesitation, sag and stumble

Check Action

Definition: Momentary lack of response as the accelerator pedal is pushed down. Can occur at any vehicle speed.

Usually more pronounced when first trying to make the vehicle move, as from a stop sigN•may cause the engine to stall

if severe enough.




Sensor/system Inspect the heated oxygen sensors. The heated oxygen sensors should respond quickly to

different throttle openings. If not, inspect the HO2S for silicon or other contaminants from fuel or

use of improper sealant. The sensors may have a white powdery coating. Silicon contamination

causes a too high but false HO2S signal voltage (rich exhaust indication). Refer to the "Silicon

contamination of heated oxygen sensors notice". The PCM will reduce the amount of fuel

delivered to the engine, causing a severe drivability problem.

Inspect the crankshaft position sensor on the scan tool. If it is not responding, inspect the sensor

feed circuit.

Inspect the TP sensor and related wiring.

Inspect MAP sensor and related wiring.

Fuel system Inspect the fuel pressure. Refer to the 'Test of fuel system pressure".

Inspect for contaminated fuel. Refer to the "Alcohol/contaminants" in the "Fuel diagnosis".

Inspect the injectors.

Inspect items which can cause an engine to run rich.

Inspect items that can cause an engine to run lean.


Inspect the coils for cracks, carbon tracking/arcing or a resistance value outside the specified

range. The coil resistance is 11-15 kilo ohms

Inspect the spark plug wires for signs of arcing/cross firing, cracks, carbon tracking, plug boot

damage, pinched, improper routing or a resistance value outside the specified range.

Important: Spraying the secondary ignition wires with a light mist of water may help locate an

intermittent problem. The ignition components will arc to ground when a secondary ignition


Defective module

Ignition system wiring - loose ignition module feed or ground connection, or damaged system

wiring


Fouled plugs

Cracks

Chafing

Improper gap


Correct model




6.4C.4.114 Power failure or insufficiency

Examination Action

Definition: engine speed is pulsating continuously or non-uniform, usually more obviously with engine load increase.

Preliminary checks

Refer to the "Check of powertrain on-board diagnostic (OBD) system".



Fuel system

Inspect the fuel pressure. Refer to the 'Test of fuel system pressure".

Inspect the injectors.

Inspect for contaminated fuel. Refer to the "Alcohol/contaminants" in the "Fuel

diagnosis".

Sensor / System

1. Inspect the conditions causing incorrect idling: Throttle clogged, sediment excessive or damaged - refer to "Instructions

of fuel metering system components". Clogging of air intake system Vacuum leak 2. Inspect the throttle position sensor and associated circuit wires. Refer to

"High voltage of throttle position (TP) sensor". 3. Inspect if the operation of crankcase forced ventilation is normal. Refer to the “Instructions of crankcase ventilation system”. 4. Check if the following components are damaged: Crankshaft position sensor is damaged


Power failure or insufficiency (continued)

Examination Action

Ignition system

If the spark is not present at the plugs, inspect for the following conditions:

Inspect the coils for cracks, carbon tracking/arcing or a resistance value

outside the specified range. The coil resistance is 11-15 kilo ohms

Inspect the spark plug wires for signs of arcing/cross firing, cracks, carbon

tracking, plug boot damage, pinched, improper routing or a resistance value

outside the specified range.

Important: Spraying the secondary ignition wires with a light mist of water may

help locate an intermittent problem. The ignition components will arc to ground

when a secondary ignition component is faulty.


Ignition system wiring - loose ignition module feed or ground connection, or

damaged system wiring


Fouled plugs

Cracks

Chafing

Improper gap


Correct model

If the spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs.

Check the following intermittent ignition system conditions；

Crankshaft position sensor signal is intermittent. The connection of ignition power-supply circuit or sensor grounding

circuit to crankshaft position sensor is intermittent.

Engine mechanical

Inspect the engine for the following conditions: Check of compression Sticking or leaking valves Camshaft lobes worn Valve timing Worn rocker arms Broken valve springs Excessive oil in combustion chamber - leaking valve seals

Too low cylinder compression For the incorrect basic engine parts, inspect for the following: Camshaft Cylinder head Pistons, etc

Additional examination

Inspect the exhaust system for possible restriction.

Inspect the exhaust system for damaged or collapsed pipes. Inspect the mufflers for heat distress or possible internal failure Inspect for possible plugged three-way catalytic converter.

The electromagnetic interference (EMI) on the reference circuit can cause an

engine misfire condition. EMI can usually be detected by monitoring engine RPM

with a scan tool. A sudden increase in RPM with little increase in actual engine

RPM indicates the EMI is present. If a problem exists, check the routing of

secondary ignition wires of high voltage components (near the ignition control

circuits).

Inspect for intake and exhaust manifold passages for casting flash.

Inspect for a faulty motor mount.


6.4C.4.115 Poor fuel economy

Check Action

Definition: Fuel economy, as measured by an actual road test is noticeably lower than the expected value. Also, the fuel economy is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.

Preliminary checks Refer to the "Check of powertrain on-board diagnostic (OBD) system". Refer to the "Intermittent conditions". Search for bulletins. Observe the owner’s driving habits: Is the A/C used frequently? Are the tires at the correct pressure? Are the tires blocked? Are excessively heavy loads being carried? Is acceleration too much, too often?

Fuel system Inspect the fuel pressure. Refer to the "Test of fuel system pressure". Inspect for the fuel injector. Inspect for contaminated fuel. Refer to the "Alcohol/contaminants" in the "Fuel

diagnosis". Ensure that each injector harness is connected to the correct injector/cylinder.

Sensor/system Inspect for crankshaft position and camshaft position sensors on the scan tool. If both are not responding, inspect the sensor feed circuit.

Check the air intake system and crankcase for air leaks. Inspect for proper calibration of the speedometer.

Ignition system If the spark is not present at the plugs, inspect for the following conditions: Inspect the coils for cracks, carbon tracking/arcing or a resistance value outside the

specified range. The coil resistance is 11-15 kilo ohms Inspect the spark plug wires for signs of arcing/cross firing, cracks, carbon tracking, plug

boot damage, pinched, improper routing or a resistance value outside the specified range.

Important: Spraying the secondary ignition wires with a light mist of water may help locate an intermittent problem. The ignition components will arc to ground when a secondary ignition component is faulty. Defective ignition module Ignition system wiring - loose ignition module feed or ground connection, or damaged

system wiring. Remove the spark plugs and inspect for the following: Fouled plugs Cracks Chafing Improper gap Burned or damaged electrodes Correct model If the spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs.

Engine cooling system Inspect the engine coolant for proper level. Inspect for an incorrect or faulty engine thermostat. Refer to the "Thermostat diagnosis

(Slow Warm Up) and "Thermostat Diagnosis (Overheating)" in the "Engine cooling".

Engine mechanical Inspect the engine for the following conditions: Check of compression Sticking or leaking valves Camshaft lobes worn Valve timing Worn rocker arms Broken valve springs Excessive oil in combustion chamber - leaking valve seals

For the incorrect basic engine parts, inspect for the following: Camshaft Cylinder head Pistons, etc

Additional checks Inspect for a restricted exhaust system: Inspect the exhaust system for damaged or collapsed pipes. Inspect the muffler for heat distress or possible internal failure. Inspect for possible plugged three-way catalytic converter.


6.4C.4.116 Rough, unstable or incorrect idle and stalling

Check Action

Definition: The engine runs unevenly at the idle speed. If severe, the engine or vehicle may shake. The engine idle

speed may vary. Either condition may be severe enough to stall the engine.




Fuel system Inspect for fuel pressure. Refer to the "Test of fuel system pressure".

Check the condition of the injector.

Inspect for contaminated fuel.

Ensure each injector harness is connected to the correct injector/cylinder.

Sensor/system Inspect for conditions which cause an incorrect idle speed:

Throttle body tampering, excessive deposits or damage - Refer to the "Description of

fuel metering system component".

Restricted air intake system.

Large vacuum leak.

Check the following items:

Check for the proper Positive Crankcase Ventilation (PCV) operation.

Check the TP sensor and related wiring.

Check for the proper sensor circuit voltage.

Ignition system If there is no spark on the plug, inspect for the following conditions:

1. Inspect the coils for cracks, carbon tracking/arcing or a resistance value outside the


2. Inspect the spark plug wires for signs of arcing/cross firing, cracks, carbon tracking,

plug boot damage, pinched, improper routing or a resistance value outside the

specified range. The spark plug wire resistance is 1.8-6.4 kilo ohms/ft.


an intermittent problem. The ignition component will arc to ground when a secondary ignition




system wiring

Remove the spark plugs and inspect for the following conditions:

Fouled plugs

Cracks

Chafing

Improper gap


Correct model



Engine mechanical Inspect the engine for the following conditions:

Check of compression

Sticking or leaking valves

Camshaft lobes worn

Valve timing

Worn rocker arms

Broken valve springs

Excessive oil in combustion chamber - Leaking valve seals

For incorrect basic engine parts, inspect for the following:

Camshaft

Cylinder head


Check Action

Pistons, etc

Additional checks Inspect for a restricted exhaust system.


Inspect the muffler for heat distress or possible internal failure.

Inspect for possible plugged three-way catalytic converter.


The electromagnetic interference (EMI) on the reference circuit can cause an engine misfire

condition. EMI can usually be detected by monitoring engine RPM with a scan tool. A

sudden increase in RPM with little increase in actual engine RPM indicates the EMI is

present. If a problem exists, check the routing of secondary ignition wires of high voltage

components (near the ignition control circuits).


Inspect for intake and exhaust manifold passages for casting flash.

6.4C.4.117 Dieseling and run-on

Check Action

Definition: The engine continues to run after the key is turned off, but runs very roughly. If the engine runs smoothly,

check the ignition switch and adjust it.




Fuel system Inspect for the fuel injector.

Additional checks Inspect for a short between the battery positive voltage and any of the ignitions feed

circuits.


6.4C.4.101 Backfiring

Check Action

Definition: The fuel ignites in the intake manifold, or in the exhaust manifold, making a loud popping noise.




Sensor/system Inspect for the following intermittent ignition system conditions:

Intermittent crankshaft position signal

Intermittent ignition feed circuit or sensor ground circuit to the crankshaft position

sensor

Inspect for the MAP sensor.

Fuel system Inspect for the too low fuel pressure. Refer to the "Test of fuel system pressure".

Inspect for contaminated fuel. Refer to the "Alcohol/contaminants in the "Fuel

diagnosis".

Ensure each injector harness is connected to the correct injector/cylinder.

Ignition system If there is no spark on the plug, inspect for the following conditions:



Spark plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug boot

damage, pinched, improper routing or a resistance value outside the specified range.


an intermittent problem. The ignition component will arc to ground when a secondary ignition


Ignition module damage


system wiring

Remove the spark plugs and inspect for the following conditions:

Fouled plugs

Cracks

Chafing

Improper gap


Correct model



Engine mechanical Inspect the engine for the following conditions:

Check of compression

Sticking or leaking valves

Camshaft lobes worn

Valve timing

Bent push rod

Worn rocker arms

Broken valve springs

Excessive oil in combustion chamber - leaking valve seals

Too low cylinder compression

For incorrect basic engine parts, inspect for the following:

Camshaft

Cylinder head

Pistons, etc

Additional checks Inspect for intake and exhaust manifolds for casting flash.

Inspect for a restricted exhaust system.


Inspect the muffler for heat distress or possible internal failure.

Inspect for possible plugged three-way catalytic converter. Refer to the "Exhaust

leakage" in the "Check of engine exhaust and restricted exhaust system".


6.4C.4.119 Diagnosis of engine control module

Check of engine diagnostic system

Important: Understanding the table and using it correctly will reduce the diagnostic time and prevent the unnecessary

replacement of parts.

After the completion of visual inspection, the "Check of powertrain on-board diagnostic (OBD) system" should be

performed. The "Check of OBD system" will provide the direction of diagnosing the following conditions:

The engine control module (ECM) inoperative or damaged, no ECM data, or service engine soon (refer to

Malfunction indicating lamp), MIL inoperative

The DTCs of ECM

The too rich or too lean fuel system

The symptoms of customer complaint drivability

The "Check of powertrain on-board diagnostic (OBD) system" is designed as a master table for drivability and emissions

system diagnosis. It should always be used as the starting point for the powertrain diagnosis. It is an organized

approach for identifying a problem. The Driver's comments normally fall into one of the following areas:

Steady MIL indicating “service engine soon”

Drivability problem

The engine will not start or stalls after start

Use of diagnostic procedure

The diagnostic procedure used in this chapter is designed to find and repair the powertrain related problems. The

general approach is to find the appropriate diagnosis scheme for a problem with five basic steps described below.

Understand the complaints of customers. It is critical that the technician understands what the customers' complaint

is; Otherwise, this may lead to the misdiagnosis or unnecessary diagnosis. Among other things, the technician

must know whether the condition is present at all times, only under certain circumstances, or truly intermittent

(random). This will assist the technician in duplicating and diagnosing the problem. Another reason the technician

must understand the customers' complaint is that the technician may determine whether the complaint requires

service or is the normal vehicle operation. Trying to diagnose a complaint that is normal will waste time and may

result in the unnecessary service.

Are the diagnostics working properly? Use the "Check of powertrain on-board diagnostic (OBD) system". This is

the starting point for the diagnostic procedure. Always begin here.

Are the DTCs displayed? If a DTC is identified by diagnostics, the "Check of powertrain on-board diagnostic (OBD)

system" will direct you to the appropriate table.

Is the customers' complaint related to a specific powertrain subsystem? If no related DTCs are set, the next

quickest way to locate the problem is to narrow it down to a specific powertrain subsystem. If a specific subsystem

can be pinpointed as the cause, it is easier to diagnose.

Is the problem powertrain related? Some customers' complaints may appear to be powertrain related but are

actually caused by other vehicle systems.


Basic knowledge required

You must be familiar with some of the basics to use this section of the service manual. They will help you to follow

diagnostic procedures in this section.

Basic electrical circuits

You should have an understanding of basic electricity and know the meaning of voltage (volts), current (amps), and

resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire and you should be

able to identify a shorted or open circuit using a DMM.

Use of digital multimeter (DMM)

You should be familiar with the digital multimeter (DMM). You should be able to use the DMM to measure voltage (volts),

resistance (ohms), current (amps), capacitance (farads), intermittent (min/max) and frequency (Hertz).

Use of circuit testing tools

You should only use a test lamp when a diagnostic procedure refers to its use. You should know how to use fused

jumper wires to test components and allow DMM readings without damaging terminals. You should know how to use a

connector test adapter kit, and use it whenever diagnostic procedures call for front probing any connector.

PCM service precautions

The PCM is designed to withstand the normal current draws associated with vehicle operations. However, care must be

used to avoid overloading any of these circuits. In testing for opens or shorts, do not ground or apply voltage to any of

the PCMs unless instructed to do so by the diagnostic procedures. These circuits should only be tested using the DMM.

Whenever a PCM removal or replacement is performed, follow the procedures in this chapter.

Damage of electrostatic discharge

The electronic components used in the control systems are often designed in order to carry very low voltage.The

electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static

electricity can cause damage to some electronic components. There are several ways for a person to become statically

charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a

person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a

highly charged object and momentarily touches ground. Charges of the same polarity are drained off, leaving the person

highly charged with the opposite polarity. Static charges can cause damage. Be careful when handling and testing the

electronic components.

Aftermarket (add-on) electrical and vacuum equipment

The aftermarket (add-on) electrical and vacuum equipment is defined as any equipment installed on a vehicle after

leaving the factory where the vehicle was originally assembled that connects, in any way, to the vehicles electrical or

vacuum systems. No allowances have been made in the design of this vehicle for this type of equipment. Therefore,

addition of aftermarket equipment must be done with the utmost care for the vehicle.


Visual underhood inspection

One of the most important checks is a visual underhood inspection. This can often fix a problem. These quick checks

take only a few minutes, can save valuable time, and help you correct the problem. For further information, refer to the

"Visual inspection" in the "Symptoms".

All the powertrain diagnoses should begin with a thorough visual inspection. The visual inspection can often lead to

repair of a simple problem without use of the tables.

Inspect all vacuum hoses for being pinched, cut, disconnected, or misrouted.

Inspect for proper ground connections, ground eyelets connected to ground points, star washers installed, if

applicable.

Inspect the battery positive junction block for loose retainer nuts.

Inspect other wiring in the engine compartment for good connections, burned, or chaffed spots, pinched wires, or

harness contact with sharp edges or hot exhaust manifolds.

Inspect for blown or missing fuses and for relays missing or installed in the wrong locations.

Use of diagnostic trouble code (DTC) tables

When diagnosing this powertrain, you will almost certainly need to use the diagnostic procedures in this or other

powertrain sections. The diagnostic procedures are mostly in the form of tables. The beginning of each DTC will be

notes about the circuit description and condition or the DTC diagnosed in the table. Reading the diagnostic support

information will help you understand the system being tested, the components involved in the test, how the PCM tests

the system (enabling conditions), how the PCM determines that the diagnostic has failed (conditions for setting the DTC),

and what the table is trying to accomplish.

Below are examples of the diagnostic support information and tables for DTCs:

Circuit description

The circuit description explains the sensor and/or circuits involved in setting the DTC. It also gives a brief description of

the time when the DTC is set.

Conditions of running the DTC

The running conditions (enabling conditions) are the conditions that must be met before the PCM will test the

sensor/system. These conditions are generally set up so that the sensor/system may be reliably inspected without a

false failure indication.

Conditions for setting the DTC

The setting conditions are the conditions that must be met for the DTC to set. A sensor/system is checked only after the

running conditions (described above) are met. If the enabling conditions are met, and the PCM detects an abnormal

sensor/system condition, the appropriate DTC is set.

Actions taken when the DTC is set

The actions taken are the steps the ECM takes after the DTC is set. These actions serve one of three purposes:

To inform the driver of the problem

To preserve the drivability of the vehicle

To prevent the failure from causing any damage to the vehicle

Conditions for clearing the MIL / DTC

These are the conditions that must be met to turn OFF the MIL, and/or clear the DTC.

Diagnostic aids

The "Diagnostic aids" provide the helpful information when the conditions that caused the DTC or drivability problem is

not currently present. Sometimes, with the help of snapshot on DTC set data (Freeze frame or failure records) or

information from the driver, the problem may still be identified or at least narrowed down to a short list of possible

intermittent conditions. When this is true, the diagnostic aids may explain what to look for, and the most logical path to

locate an intermittent condition.


Test description

Test descriptions are explanations of the reason why certain inspections are done, and what the inspection is supposed

to uncover. The information is numbered according to the corresponding step in the diagnostic table. For the questions

of why a certain step is performed, or what results the step should actually produce, observe the step number next to the

check you are performing. Refer to the information under the "Test description" that has the same number for an

explanation.

Diagnostic tables

Diagnostic tables are an organized and systematic approach to diagnosing a diagnostic trouble code (DTC). The table

consists of five separate columns: Step number, action, value, yes and no. The step number indicates which step is

being performed. The "Action" column contains all necessary information about how to perform a certain test. The last

sentence in each action block will always be a question. The question can only be answered yes or no. The answer to

the question will dictate which column you will go to next YES or NO. The yes or no answer to each test will lead to the

next logical step within the diagnostic table. Most of the YES and NO boxes will take you to the next logical step within

the table. However, some boxes may lead to other system diagnostics or to the diagnostic aids when an intermittent

condition exists.

Always begin with Step 1 at the top of the table unless there is a notice or caution above it. Never skip steps or jump

ahead in the table unless specified by the Yes/No columns. Taking short cuts often leads to misdiagnosis. When a

problem is found, make the necessary repairs, and then verify the repair.

Verification of repair

Confident verification of a DTC repair can only be done by matching the test descriptions of the DTC and ensuring that

the DTC RUNS and PASSES. To know if a test runs and passes, use the scan tool and select DTC Status and note the

DTC that needs verification. The status of the diagnostic test can be now observed. For symptom repairs, drive the

vehicle and ensure the symptom is gone.

Checking terminal contact

Many tables will have you inspect the terminal contact before replacing a component. This is done because the checks

performed in tables can only check the continuity of a circuit across a wire or in-line connection, not the continuity across

the connection at a component. Checking the terminal contact will prevent the replacement of good components,

prevent comebacks due to intermittent connection problems, and make some repair jobs easier, as in replacing a

terminal instead of a component. For this reason, it is very important to inspect the terminal contact when instructed to

do so.

Inspecting the terminal contact is easy as long as you have a supply of new terminals handy. The terminal repair kit is a

good source of terminals for inspecting the terminal contact. It contains a supply of all currently used terminal series. To

inspect the terminal contact, start by inspecting the male terminals. They should be straight and aligned with other

terminals in the row. They should not be twisted, bent or otherwise damaged. The female terminal should be, likewise,

inspected for alignment and damage. Finally, take a new male terminal of the same series (e.g. Metri-pack 150,

Weatherpack, etc.) and connect it to the female terminals to be checked. It should not fall out or be easily jarred out of

connection. It should require some force to disconnect it. The force required to disconnect it will depend on the size of

the terminal being checked. Larger terminals, Metri-pack series for example, should be easier to disconnect by hand but

still should not fall out. Replace, do not repair, any damaged terminals.

Diagnosis of intermittent trouble

Diagnosing intermittent conditions can be difficult. The conditions for setting the DTC may not be present. This does not

mean that the problem is fixed. It simply means that the problem intermittently occurs. The problem may return in the

future. So, if at all possible, the problem should be diagnosed, and repaired. The only way to diagnose an intermittent

condition is to gather information from the time when the DTC was set. This can be done in two ways, through snapshot

data and driver observations. For further information, refer to "Snapshot procedure of scan tool".


6.4C.4.120 The air-conditioning circuit controlled by engine control module

System diagnosis

Circuit description (Control schematics of A/C compressor)

When the A/C is selected through the HVAC controller, a signal is supplied to the control module through the A/C switch

circuit. The A/C relay is controlled through the ECM. The control module monitors the A/C refrigerant pressure. If the

A/C refrigerant pressure and engine operating conditions are within the specific calibrated acceptable ranges, the ECM

will enable the A/C relay. This is accomplished by providing a ground path for the A/C relay coil within the ECM. When

the A/C compressor relay is enabled, the battery positive voltage is supplied to the compressor clutch coil.

The ECM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested,

unless any of the following conditions are met:

The vehicle speed is less than 110 km/h for running within 6 seconds if full loaded; The changing rate of TP angle is

more than 105o/s. If the vehicle speed is less than 15 km/h, the engine speed is less than 1408 rpm.

The engine's water temperature is above 113°C, while the A/C thermistor temperature is above 7.06 C.

In the dwell time after starting the engine, specific value depends on the starting water temperature and altitude. At

plain areas, the dwell time differs from 5-8 seconds according to different starting water temperatures.

Within 9 seconds after turning off the A/C.

Air conditioning (A/C) evaporator temperature is below 3 °C.

The battery voltage is below 10V.

Within 8 seconds after pressing the accelerator pedal to the wide open position.

Diagnostic aids

Inspect for the following items:

Important: Remove any debris from the connector surfaces before servicing a component. Inspect the connector

gaskets when diagnosing or replacing a component. Ensure that the gaskets are installed correctly. The gaskets

prevent the contaminant intrusion.

Poor terminal connection - Inspect the harness connectors for backed out terminals, improper mating, broken locks,

improperly formed or damaged terminals, and faulty terminal-to-wire connection. Use a corresponding mating

terminal to test for proper tension.

Damaged harness - Inspect the wiring harness for damage. If the harness inspection does not reveal a problem,

observe the display on the scan tool while moving the wiring harnesses related to the sensor. A change in the scan

tool display may indicate the location of the fault.

Inspect the PCM and engine grounds for clean and secure connections.

If the DTC is determined to be intermittent, reviewing the Failure Records can be useful in determining when the DTC

was last set.


Examination of air-conditioning circuit controlled by powertrain control module


1. Did you perform the "Check of powertrain on-board

diagnostic (OBD) system"? - Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

2. Are all of the ECM or HVAC DTCs stored? -

Diagnose the

appropriate

DTCs

Go to Step 3

3.

Important: The following conditions must be met before

continuing with this step:

The A/C evaporator temperature must be above

3°C.

The coolant temperature must be below 113°C.

1. Turn the A/C selector switch to the OFF position.

2. Turn on the ignition, with the engine off.

3. Test for the engagement of the A/C system clutch or

A/C clutch.


4.

1. Start and operate the engine at 1000-1500 RPM.

2. Turn the A/C selector switch to an A/C mode.

3. Observe for the engagement of the A/C system

clutch or A/C clutch.

-

Refer to

"Diagnostic

aids"

Go to Step 5

5.

1. Leave the A/C selector switch turned to an A/C

mode.

2. Observe the A/C request display on the scan tool.

Does the A/C request display YES?


6.

Observe the A/C pressure sensor display on the scan

tool.

Does the A/C pressure sensor indicate a voltage

between the specified values?

0.4V - 4.6V

Go to "A/C

system" in

"HVAC"

Go to Step 7

7.

1. Connect a refrigerant recovery, recycling, and

recharging (ACR4) to monitor high side refrigerant

pressure.

2. Observe high side refrigerant pressure on the

refrigerant recovery, recycling, and recharging

(ACR4) gauge.

Is high side refrigerant pressure within the specified

values?

35psi -

440psi

Go to " A/C

system

diagnosis" in

"HVAC" system

Go to "Air

conditioning

(A/C) refrigerant

pressure sensor

circuit"

8. Inspect the A/C clutch fuse.

Is the A/C cutch fuse blown? - Go to Step 9 Go to Step 10

9.

1. Remove the A/C clutch fuse.

2. Remove the A/C relay.

3. Test for the following circuit conditions:

Short to ground in the battery positive feed to the

A/C relay.

Short to ground in the battery positive feed to the

A/C clutch.

Shorted diode.

4. If a problem is found, repair as necessary.



10. 1. Remove the A/C relay. - Go to Step 12 Go to Step 11



2. Connect a jumper wire with a 10A fuse between the

battery positive pole and A/C clutch coil power

supply socket in the relay connector.

Is the A/C clutch connected?

11.

Test for the following circuit conditions:

1. Open in the battery positive feed circuit to the A/ C

relay.

2. Open in the battery positive feed circuit to the A/ C

clutch.

3. Open in the A/C clutch ground circuit.

4. Poor terminal connections in the A/C clutch coil

connector.



12.

Test for poor terminal connections of A/C Relay in the

accessory wire junction block under engine cover. If poor

terminal connection is found, replace the accessory wire

junction block under engine cover.

Is failure found and corrected?


13.

● Turn the ignition OFF.

● Remove the A/C relay.

● Turn on the ignition. Is the A/C clutch engaged?


14. Disconnect the A/C clutch connector.

Is the A/C clutch engaged? - Go to Step 15 Go to Step 17

15. Replace the A/C clutch.


16. Replace the A/C relay compressor.


17.

Locate and repair a short to voltage in the battery positive

feed circuit to the A/C clutch.


- Go to Step 18 -

18.

Important: The following conditions must be met before

continuing with this step:

The A/C evaporator temperature is above 3°C.

The coolant temperature must be below 113°C.

1. Start the engine and let it run at a speed of

1000-1500rpm.

2. Switch on the A/C system option switch.

3. Listen to the connecting sound of the A/C clutch.

4. Wait for 5s and switch off the A/C gear selection

switch.

5. listen to the disconnecting sound of the A/C clutch.

Is the A/C clutch connected and then disconnected?

- System OK Go to Step 3


6.4C.4.121 Diagnosis of electric cooling fan

Refer to the "Engine cooling fan"

Circuit description

The fan motor is supplied through the wiring junction block. The cooling fan relays are energized and the fan operates

when the current flows from the fan control fuse and main relay control fuse in the wiring junction block through the relay

coils to ground through the powertrain control module (PCM).

Diagnostic aids

If the owner complained of an overheating problem, determine if the complaint was due to an actual boil over, the

warning indicator illuminated, or the engine coolant temperature (ECT) gauge indicated overheating. The gauge

accuracy can also be checked by comparing the ECT sensor reading using a scan tool and comparing its reading with

the gauge reading. If the engine is actually overheating and the gauge indicated overheating, but the cooling fans are

not turning on, the ECT sensor may have shifted out of calibration and should be replaced. If the engine is overheating

and the cooling fans are on, the cooling system is suspected and should be checked.

Inspect for the following conditions:

Poor connection at the PCM, cooling fan relays or cooling fan motors - Inspect the harness connectors for:

Backed out terminals

Improper mating

Broken locks


A poor terminal-to-wire connection.

Test description

The numbers below refer to step numbers in the diagnostic table:

1. The PCM will enable the engine cooling fans when the certain diagnostic trouble codes (DTCs) are set. Refer to

the applicable DTC table first before proceeding with this table.

2. Allow the engine coolant temperature to cool below 88-100°C before proceeding with the diagnosis.

3. Fan operating conditions:

When the water temperature exceeds the threshold value (98°C), regardless of any other condition, the engine

cooling fan should be ON.

A/C OFF at the idle speed: When the water temperature is below the threshold value (93°C), the engine cooling fan

should be OFF.

A/C ON: The A/C fan keeps running.


Diagnosis of electric cooling fan



diagnostic (OBD) system"? - Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

2. Are any DTCs set? -

Go to the

appropriate

DTCs

Go to Step 3

3.


2. The engine coolant temperature must be below the

specified value for all the fan diagnoses.

3. Turn ON the ignition, with the engine and A/C OFF.

Are the cooling fans OFF?

89°C Go to Step 4 Go to cooling

fan table #1

4. With a scan tool, command engine cooling fans on.

Are the engine cooling fans operative? - Go to Step 5

Go to cooling

fan table #2

5.

Important note: Allow 3-5 seconds before determining if

the fans have switched from low to high speed. Give

instructions of high speed to the fans through .

- Go to Step 6 Go to cooling

fan table #3

6.

1. Exit outputs screen on the scan tool.

2. Idle the engine leaving the A/C OFF.

Are the cooling fans ON?


7. Turn ON the A/C.

Are the cooling fans ON? - System OK Go to Step 9

8. Does the scan tool display A/C request as YES? -

Go to "A/C

system

diagnosis in

HVAC"

Go to Step 10

9. Does the scan tool display A/C request as YES? -

Go to "Diagnosis

of PCM

controlled A/C

circuit"

Go to "A/C

system

diagnosis in

HVAC"

10. Replace the ECM. Is the action complete? - System OK -


6.4C.4.122 Check of fuel tank leak

Note:

Before attempting the check of fuel tank leak, place a dry chemical fire extinguisher near the work area.

Before removing the fuel tank for a suspected leak, make sure the fuel hoses are not leaking onto the tank. Also,

make sure the fuel is not leaking around the fuel sender gasket.

1. Relieve the fuel system pressure. Refer to the "Fuel pressure relief procedure".

2. Remove the fuel tank. Refer to the "Replacement of fuel tank".

3. Plug all outlets as follows:

Install the filler neck and vent hoses, upper neck assembly, and install the filler cap.

Install the fuel tank sender with seal, and plug fuel lines.

Install a short piece of fuel line on fuel tank meter vent tube.

4. Apply the air pressure to tank through a vent tube. Approximately 7 to 10 kPa (1 to 1.5 psi), pinch the fuel filler hose

to retain the pressure.

5. Test the suspected area for leaks with soap solution or by submersion. If any leak is noted, replace the tank. Refer

to the "Replacement of fuel tank".

6.4C.4.99 Alcohol/contaminants-in-fuel diagnosis

Alcohol concentrations greater than 10 percent in fuel can be detrimental to fuel system components and may cause

drivability problems such as hesitation, lack of power, stall, no start, etc.

The problems may be due to fuel system corrosion and subsequent fuel filter plugging, deterioration of rubber parts,

and/or air-fuel mixture leaning.

Various types and concentrations of alcohol are used in commercial fuel. Some alcohol is more detrimental to fuel

system components than others. If an excessive amount of alcohol in the fuel is suspected as the cause of a drivability

condition, the following procedure may be used to detect the presence of alcohol in the fuel.

Note

The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The

sample should be bright and clear. If the sample appears cloudy or contaminated with water (as indicated by a water

layer at the bottom of the sample), this procedure should not be used and the fuel system should be cleaned.

1. Use a 100 ml specified cylinder with 1 ml graduation marks, and fill the cylinder with fuel to the 90 ml mark.

2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper.

3. Shake the cylinder vigorously for 10 to 15 seconds.

4. Release the pressure inside and listen to the sound of the stopper closely.

5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds.

6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation.

If the alcohol is present in the fuel, the volume of the lower layer (which would now contain both alcohol and water) will

be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent

water in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of

the alcohol from the fuel.


6.4C.4.123 Diagnosis of electronic ignition (EI) system

Refer to the "Schematics of engine control system".

The secondary ignition check tests for faulty spark plugs, plug wires, or IC module and coils.

Diagnosis of electronic ignition equipment (EI) system



diagnosis (OBD) system"? - Go to Step 2

Go to "Check of

powertrain

on-board

diagnostic

(OBD) system"

2. Test for spark at each cylinder. Did you observe any

non-sparking cylinders? - Go to Step 3 Go to Step 6

3.

Note: It is possible for an arching spark plug wire to IC

module or arching ignition coil to IC module to cause a

stall or no start condition.

Inspect and test the affected cylinder spark plug wires,

ignition coils, and spark plugs for a short to ground or

arching to ground. If carbon tracking or corrosion is

present, replace both components affected.

Did you find and correct the conditions?

-

Go to "Check of

powertrain

diagnostic

(OBD) system"

Go to Step 4

4.

Test the affected spark plug wires for proper resistance.

Replace the spark plug wires not near specification.

Did you find and correct the conditions?

Go to "Check of

powertrain

diagnostic

(OBD) system"

Go to Step 5

5.

Switch the affected cylinder coil with a known good one.

If the fault follows the affected coil, replace it.


-

Go to "Check of

powertrain

diagnostic

(OBD) system"

Go to Step 10

6.

Inspect the spark plug wires for proper routing and for the

correct firing order. If any spark plug wires are found to

be misrouted, reroute as necessary.


Go to "Check of

powertrain

diagnostic

(OBD) system"

Go to Step 7

7.

With a DMM, check spark plugs for internal short to

ground. Replace any grounded spark plugs found.


-

Go to "Check of

powertrain

diagnostic

(OBD) system"

Go to Step 8

8.

1. Remove the spark plugs.

2. Inspect the spark plugs for damage. If any spark

plugs are found to be bad, replace the affected

spark plugs.


-

Go to "Check of

powertrain

diagnostic

(OBD) system"

-

9.

1. Disconnect the IC module.

2. Turn the ignition ON.

3. With a test lamp connected to a good ground, probe

the ignition control module ignition feed circuit.

Does the test lamp illuminate?


10.

1. Ensure the battery voltage is within specifications.


3. Connect a DMM between the 58X reference high

circuit and the 58X reference low circuit at the IC

module harness connector.




4. Crank the engine while observing the AC duty cycle

(%).

Does the DMM indicate the AC duty cycle present?

11.

Test the 58X crankshaft sensor circuits for the following

conditions:

a. An open circuit

b. A short to ground

c. A short to voltage

58X reference high and 58X reference low circuits

shorted together. Repair any damaged wiring.


-

Go to "Check of

powertrain

diagnostic

(OBD) system"

Go to Step 14

12.

Repair the open or short to ground in the IC module

ignition feed circuit.


-

Go to "Check of

powertrain

diagnostic

(OBD) system"

-

13. Replace the ignition control module.

Is the replacement complete? -

Go to "Check of

powertrain

diagnostic

(OBD) system"

-

14. Replace the 58X crankshaft sensor.

Is the replacement complete? -

Go to "Check of

powertrain

diagnostic

(OBD) system"

-


6.4C.5 Repair instructions

6.4C.5.1 Replacement of intake air

temperature sensor

Removal procedure 1. Disconnect the negative electrode of battery, open

the right front seat. 2. Disconnect the plug of intake temperature sensor. 3. Unplug the intake air temperature sensor. Installation procedure 1. Install the intake air temperature sensor on the

bellows. Fastening Intake air temperature sensor has an interference fit with the bellows. 2 Connect the plug of intake air temperature sensor. 3 Connect the negative electrode of battery.

13AC-06C05002

13AC-06C05001


6.4C.5.2 Intake pressure sensor

replacement

Removal procedure

1. Disconnect the battery, open the right front seat.

2. Disconnect the plug of the intake pressure sensor.

3. Loosen the fastening bolts of the intake pressure

sensor from the intake manifold.

4. Disassemble the intake pressure sensor from the

intake manifold.

Installation procedure

1. Install the intake temperature sensor onto the

intake manifold.

2. Install the fastening bolt on the intake pressure

sensor and tighten to the specified torque range.

Fastening

Tighten the fastening bolt of the intake pressure sensor

of the system to 8-12N.M.

3. Connect the plug of intake pressure sensor.

4. Connect the negative electrode of battery.

13AC-06C05004

13AC-06C05003


6.4C.5.3 Replacement of electronic throttle

valve body assembly

Removal procedure

1. Disconnect the battery, open the right front seat.

2. Disassembly the bellows according to the

“Replacement of bellows”.

3. Disassemble the fastening bolts of the electronic

throttle valve.

4. Disassemble the plug of the throttle position sensor.

5. Take off the electronic throttle valve assembly.


1. Install the electronic throttle valve assembly on the

flange of the intake manifold throttle.

2. Install the fastening bolts of the electronic throttle

valve assembly, and fasten to a torque as

requested.

Fastening

Fasten the electronic throttle valve assembly fastening

bolt to 8-12 N·M.

3. Connect the harness plug with the plug of the

throttle position sensor.


13AC-06C05006

13AC-06C05005


6.4C.5.4 Replacement of EGR Valve

Removal procedure

1. Disconnect the battery, open the front seat.

2. Disassemble the plug of EGR valve harness.

3. Disassemble the fastening bolt of EGR valve.

4. Take off the fastening support of EGR valve.

5. Take off the EGR valve.


1 Install the EGR valve and its support, and fasten

them with bolts as per requested torque.

Fastening

Fasten the EGR valve bolt to 6-10N.M.

2 Connect the harness plug to the plug of EGR valve.

3 Connect the negative electrode of battery.

13AC-06C05008

13AC-06C05007


6.4C.5.5 Replacement of air intake side VVT

actuator

Removal procedure:


2. Disconnect the harness plug of the air intake side

VVT actuator.

3. Disassemble the fastening bolt of the air intake side

VVT actuator.

4. Take off the air intake side VVT actuator.

Installation procedure:

1. Fix the air intake side VVT actuator on the engine

with fastening bolts and fasten the bolts as

requested.

Fastening

Fasten the bolts of the air intake side VVT actuator to

55-65N.M.

2. Connect the harness plug with the plug of the air

intake side VVT actuator.


13AC-06C05010

13AC-06C05009


6.4C.5.6 Replacement of front oxygen

sensor

Removal procedure

1. Disconnect the wiring harness from the oxygen

sensor plug.

2. Unscrew the front oxygen sensor off from the

three-way catalyst.


1. Install the front oxygen sensor onto the three-way

catalyst and then tighten to the specified torque.

Fastening

Fasten the front oxygen sensor to 40—60N.M.

2. Connect the wiring harness with the front oxygen

sensor plug.

13AC-06C05012

13AC-06C05011


6.4C.5.7 Replacement of back oxygen

sensor

Removal procedure

1. Disconnect the wiring harness from the back

oxygen sensor plug.

2. Unscrew the back oxygen sensor off from the tail of

the three way catalyst in the exhaust pipe.


1. Install the back oxygen sensor onto the tail of the

three way catalyst in the exhaust pipe, and then

tighten to the specified torque.

Fastening

Fasten the back oxygen sensor to 40—60N.M.

2. Connect the wiring harness to the back oxygen

sensor plug.

13AC-06C05014

13AC-06C05013


6.4C.5.8 Replacement of camshaft position

sensor

Removal procedure


2. Disconnect the harness with the phase sensor plug.

3. unscrew the fastening bolts of the phase sensor.

4. Take off the camshaft sensor.


1. Install the camshaft position sensor onto the seat of

the camshaft position sensor.

2. Install the fastening bolt of the camshaft position

sensor, and then tighten to the specified torque..

Fastening

Fasten the fastening bolt of the phase sensor to

8-12N.M.

3. Connect the harness to the phase sensor plug.


13AC-06C05016

13AC-06C05015


6.4C.5.9 Replacement of crankshaft

position sensor

Removal procedure

1. Disconnect the battery, open the left front seat.

2. Disconnect the harness with the crankshaft position

sensor plug.

3. Loosen the connecting bolt between the crankshaft

position sensor and the transmission.

4. Take off the crankshaft position sensor.


1. Install the crankshaft position sensor on the

transmission.

2. Install the crankshaft position tightening bolt and

tighten to the specified torque.

Fastening

Fasten the crankshaft position sensor to the torque of

8-12N•M.

3. Connect the harness with the crankshaft position

sensor plug.


13AC-06C05018

13AC-06C05017


6.4C.5.10 Replacement of coolant

temperature sensor

Removal procedure

1. Open the sealed cover of coolant compensation

tank, and decompress the pressure of the cooling

system. Refer to the description about "emptying

and filling cooling system" of the engine cooling

system.

2. Disconnect the harness plug from the coolant

temperature sensor.

3. Unscrew the coolant temperature sensor from the

intake manifold.

4. Collect the overflowing coolant.


1. Apply GY-340 anaerobic adhesive to the threaded

parts of the coolant temperature sensor.

2. Install the coolant temperature sensor onto the

intake manifold and tighten to the specified torque.

Fastening

Fasten the coolant temperature sensor to the

torque18-22 N•M.

3. Connect the harness plug to the coolant

temperature sensor.

4. Replenish the coolant to specified amount and

exhaust air from the cooling system. Refer to the

description about "emptying and filling cooling

system" of the engine cooling system.

13AC-06C05020

13AC-06C05019


6.4C.5.11 Replacement of knock sensor

Removal procedure

1. Disconnect the battery, open the left and right front

seats.

2. Disassemble the auxiliary dashboard, gear shift

mechanism, handbrake, table plate welded pieces.

Refer to the “Replacement of auxiliary dashboard,

gear shift mechanism, handbrake and table plate

welded pieces”.

3. Disassemble the intake manifold, refer to the

“Replacement of intake manifold”.

4. Disconnect the harness with the knock sensor plug.

5. Loosen the connecting bolts of knock sensor and

crankcase.

6. Take off the knock sensor.


1. Install the knock sensor to the corresponding

position on the crankshaft.

2. Install the knock sensor tightening bolt and tighten

to the specified torque.

Fastening

Fasten the knock sensor tightening bolt to 20±5 N•M.

3. Connect the harness patch plug to the knock

sensor.


13AC-06C05022

13AC-06C05021


6.4C.5.12 Replacement of canister solenoid

valve

Removal procedure

1. Disconnect the battery, open the right front seats.

2. Disassemble the vacuum hose connected with the

intake manifold from the canister solenoid valve.

3. Loosen the rubber hose clamp connecting the

canister solenoid valve and the canister, to

disassemble the rubber hose and clamp.

4. Loosen the fastening bolt of the canister solenoid

valve bracket.

5. Disassemble the canister solenoid valve and its

bracket.

6. Disassemble the canister solenoid valve from its

bracket.

Installation program

1. Install the canister solenoid valve onto its bracket.

2. Install the canister solenoid valve and bracket onto

the intake manifold.

3. Install the fastening bolt of the canister solenoid

valve bracket and tighten to the specified torque.

Fastening

Fasten the canister solenoid valve bracket fastening bolt

to the torque of 8-12 N·M.

4. Install the rubber hose connected to the canister

onto the canister solenoid valve, and clamp well.

5. Install the vacuum hose connected to the intake

manifold onto the canister solenoid valve.


13AC-06C05024

13AC-06C05023


6.4C.5.13 Replacement of engine module

Removal procedure

1. Disconnect the negative electrode of battery.

2. Find the ECM under the side seat.

3. Disassemble the fastening bolt of the ECM bracket.

4. Take out the ECM from the module.

5. Disconnect the harness plug with the electronic

module socket.

Warning: make sure to disconnect the battery for at

least 20 seconds before removing the module

connection.


1. Insert the harness plug into the socket on the

electronic control module.

2. Install the electronic module into the module

bracket.

3. Tighten the bolt on the module bracket.

4. Connect the negative cable to the battery.

13AC-06C05026

13AC-06C05025


6.4C.5.14 Replacement of electronic

accelerator pedal

Removal procedure

1. Find out the electronic accelerator pedal assembly

under the instrument board.

2. Disconnect the electronic accelerator pedal plug.

3. Loosen the fastening bolt of the electronic

accelerator pedal assembly.


1. Insert the electronic accelerator pedal’s harness

plug.

2. tighten the fastening bolt of the electronic

accelerator pedal bracket.

Fastening

Fasten the electronic accelerator pedal assembly

fastening bolt to the torque of 9-11 N·M.

13AC-06C05028

13AC-06C05027


6.4C.6 Descriptions and operation

6.4C.6.1 General description

The engine is equipped with an improved engine control

system. The system provides individual injectors,

controlled by the ECM (engine control module) and

energizes injectors in pair. That is to say, while the

crankshaft rotates every 180 degrees, fuel injector 1 and

4 as well as 2 and 3 will be energized once in turn. The

purpose is to ensure sufficient burning under the

condition of keeping the engine operate at the low speed

and low emission level, obtaining the maximum torque.

The ignition is directly controlled by the direct ignition

system (DIS).

Important repair instructions

Only program storage（PROM）assigned to the

vehicle is allowed to use.

Don't contact the oxygen sensor with fuel and

silicones. Don't clean it with gasoline or contact with

it.

Don't use corrosion protection on or around catalytic

converter and oxygen sensor.

The intake and exhaust system leaks (dead air) in

the front of the catalytic converter could cause the

reading mistake of oxygen sensor.

The leaks of vapor control system may cause the

fluctuation of idle-speed rotational degree.

If the injectors are leaking, the engine could

continue to run after the ignition is turned off (Diesel

effect).

If the engine is difficult to start, check the fuel

system, fuel pump relay and ignition systems.

Before removing electronic components, disconnect

the ground wiring with the battery.

After disconnecting with the battery, all the trouble

codes stored in the storage locations and

“self-learned” idle speed and mixed correction will

be cancelled.

Notice: To prevent the overheating of catalytic converter,

perform a balance test on the cylinder according to

following steps based on the order of time (if necessary):

The longest closing time of a cylinder is 8 seconds.

The minimum interval time between each opening

and closing of cylinder is 8 seconds.

6.4.6.2 Description of engine control

module(ECM)

The engine control module (ECM) is the core of the

engine management system. It controls the data from

different sensors and controllers. The information is used

to control the engine operation (fuel, spark advance

angle, A/C compressor speed). ECM is responsible for

giving full play to the engine under the condition of

minimum exhaust emission. The control module is on the

bottom right under the side seat.

6.4.6.3 Description of air intake system

This system is to collect, clean, check and control the

airflow, pass it into the intake manifold, and mix it with

fuel in the cylinder.

The system consists of the following components: air

filter, throttle body, air intake temperature sensor (IAT),

idle air control valve (IAC) and throttle position sensor

(TPS).

Electronic throttle body

The throttle body controls the airflow entering the intake

manifold. The air flowing into the engine is controlled by

the throttle valve.

6.4C.6.4 Sensor Information/ Switch

Description

Oxygen Sensor

The front oxygen sensor is in front of TWC, while back

oxygen sensor is at the tail of TWC.

The function of oxygen sensor is to monitor the content

of oxygen in exhaust gas, and send the information

related with the mixed air/ fuel proportion to ECM.

When the concentration of mixed gas is high, the data is

sent to ECM, reducing the amount of injected fuel, on the

contrary; when the concentration is low, injected fuel is

increased.

Intake Pressure Sensor

Installed on the intake manifold. The function of pressure

sensor is to measure the change of engine load and

speed, and convert the data into voltage.

Under some circumstances the absolute pressure sensor

of intake manifold can be used as below:

Measure air pressure, so as to make necessary

corrections to the engine control module (ECM), to

compensate different heights.

Engine control module (ECM) controls the delivery of fuel

and ignition advance angle using MAP sensor signal.

Intake Temperature Sensor

The function of temperature sensor is to measure the

temperature change of intake manifold on the engine,

and convert this data into the voltage.

Coolant Temperature Sensor (CTS)

Located att the top of engine thermostat seat, its function

is to report the temperature of engine coolant to engine


control module (ECM), which reflects the engine

temperature.

ECM changes the ignition advance using received

information, and changes the fuel injection according to

engine temperature. When the Coolant Temperature

Sensor shows the value of 2.7V, which is equivalent with

40 centigrade, the oxygen sensor “Closed recycling

control”.

Crankshaft Position Sensor (CPS)

The system has a serrated disc sticking close to the

pulley of transmission belt on the crankshaft, and an

inductive sensor connected to the position of the cylinder

radius which is close to the serrated disc. There are 58

teeth and one neutral position in the serrated disc, where

two teeth are missing and the degree of each tooth is 15

degree.

When the teeth pass through the sensor, the current will

change. The frequency of current changes can be

changed by the control unit and transferred to the engine

speed.

The space between two teeth may generate higher

voltage, which can inform the electronic control module

(ECM) the position of crankshaft, ECM determine the

ignition advance angle accordingly.

Vehicle Speed Sensor (VSS)

The function of this sensor is to inform the vehicle speed

to the engine control module (ECM).The module controls

the idling speed using such information, and check the

vehicle stops or running.

ECM counts the signal (rectangular pulse), and

calculates the vehicle speed with the unit of km/h.

Knock Sensor (KS)

The knock sensor (KS) of engine management systems

is self-generated piezoelectric transducer. It is mounted

on the engine body and can generate the output voltage

according to the vibration amplitude of engine caused by

the knock. When there are knock existing on sensor

signal, ECM controls the knock through adjusting ignition

advance angle.

6.4C.6.5 Fuel Rail Description

The fuel rail is mounted on the intake manifold, and its

function is to determine the position of injector, assigning

the pressed fuel to the injector.6.4C.6.6

6.4C.6.6 Fuel Injector Description

Injector is an electromagnetic coil controlled by the

electronic control module (ECM). There is a ball valve

normally kept closed, and would be open under the

action of the energized electromagnetic coil, so that the

fuel flow through the injector till the orifice. The calibrated

hole on the orifice controls the flow of fuel and forms

conical spray, which is atomized and gasified then sent

to the combustor.

6.4C.7 Special tools and equipment

Graphical representation Tool number/Name

07N06057

03

X431 DTC examination

PT-0013

Fuel pressure gage

6.4c engine control system - new 1.2l b12-mce

Documents